WO2019044200A1

WO2019044200A1 - Method for producing door for air conditioner and method for producing air conditioner for vehicle

Info

Publication number: WO2019044200A1
Application number: PCT/JP2018/026266
Authority: WO
Inventors: 洋至浜崎
Original assignee: 株式会社デンソー
Priority date: 2017-08-29
Filing date: 2018-07-12
Publication date: 2019-03-07
Also published as: JP2019042929A; JP6848768B2

Abstract

This method for producing a door for an air conditioner includes a mold clamping step in which a rod-shaped inner mold (73) that forms the inside of a tubular portion (121) and outer molds (71, 72) that have convex portions (171, 172) projecting toward the inner mold and that form the outside of the tubular portion are disposed at prescribed locations and the molds are joined, and an injection step in which a resin member is injected into a hollow portion (76) formed between the clamped inner mold and outer molds. In the mold clamping step, the inner mold and the convex portions of the outer molds are disposed in contact with each other. In the injection step, the inner mold receives the injection pressure exerted by injection of the resin member and receives from the convex portions a pressing force for pressing back the inner mold to counteract the injection pressure.

Description

Method of manufacturing door for air conditioner and method of manufacturing air conditioner for vehicle

Cross-reference to related applications

This application is based on Japanese Patent Application No. 2017-164684 filed on Aug. 29, 2017, the contents of which are incorporated herein by reference.

The disclosure in this specification relates to a method of manufacturing a door for an air conditioner and a method of manufacturing an air conditioner for a vehicle.

Patent Document 1 discloses a door drive mechanism of a vehicle air conditioner having a cylindrical rotation shaft portion. In the case of injection molding a cylindrical rotary shaft, there is known a method of forming a rod-like slide mold outside the rotary shaft in order to mold a hollow portion inside the cylindrical rotary shaft.

JP, 2013-35379, A

In the configuration of the prior art, the rod-like mold is deformed by being pushed by the resin member injected at the time of injection molding, and the coaxiality of the cylindrical rotation shaft may be deteriorated. That is, the injection molded product may be deformed, for example, when the cylindrical rotary shaft portion is formed in a warped shape. When a cylindrical air conditioner door deformed into an air conditioner is used, the rod-like rotary shaft inserted into the cylindrical rotary shaft and the cylindrical rotary shaft rub against each other, etc. There was a case that occurred. In the above aspects, or in other aspects not mentioned, there is a need for further improvements in the method of manufacturing the door for the air conditioner and the method of manufacturing the air conditioner for the vehicle.

One object disclosed is to provide a method of manufacturing an air conditioner door in which the coaxiality of the tubular portion is improved.

Another object disclosed is to provide a method of manufacturing a vehicular air-conditioning system in which the occurrence of malfunction due to rubbing of two rotating shafts or the like is suppressed.

The method of manufacturing a door for an air conditioner disclosed herein includes a rod-like inner mold forming the inner side of the cylindrical part, and a convex part projecting toward the inner mold so that the outer side of the cylindrical part is formed. A mold clamping process in which molds are combined by arranging an outer mold to be formed at a predetermined position, and injecting the resin member into a cavity formed between the clamped inner mold and the outer mold And a process. In the mold clamping process, the inner mold and the convex part of the outer mold are placed in contact with each other. In the injection process, the inner mold receives an injection pressure that is pushed by the injection of the resin member, and receives a pressing force that pushes back the inner mold from the convex portion so as to resist the injection pressure.

According to the disclosed method of manufacturing a door for an air conditioner, in the injection process, the inner mold receives a pressing force that pushes back the inner mold from the convex portion so as to resist the injection pressure. That is, deformation such as bending of the inner mold is suppressed by the pressing force of the convex portion being applied in the direction to resist the injection pressure of the resin. For this reason, in injection molding, it can suppress that the door for air conditioners is shape | molded in the state which the inner side metal mold was deformed by injection pressure.

The vehicle air conditioner disclosed herein includes an air conditioning case through which the air supplied into the vehicle compartment passes, a partition plate that divides the inside of the air conditioning case into a first air passage and a second air passage, and a first air passage. , A second door for opening and closing the second air passage, a first rotary shaft portion for rotating the first door, and a through hole provided on the side surface for rotating the second door. And a second rotation shaft portion. The second door is an air conditioner door manufactured by the above manufacturing method. The method of manufacturing the vehicle air conditioner includes the step of axially arranging the first door and the second door and attaching the first door and the second door to the air conditioning case in a state where the first rotating shaft portion is inserted into the second rotating shaft portion.

According to the disclosed method of manufacturing a vehicle air conditioner, the first rotation shaft portion is inserted into the second rotation shaft portion having high coaxiality. That is, it can suppress that the 1st rotating shaft part which rotates the inside of the 2nd rotating shaft part rubs inside the 2nd rotating shaft part. For this reason, generation | occurrence | production of the noise by the friction with a 1st rotating shaft part and a 2nd rotating shaft part, and operation defects, such as excess of operation force, can be reduced.

The disclosed aspects in this specification employ different technical means in order to achieve their respective goals. The reference numerals in the parentheses described in the claims exemplify the correspondence with parts of the embodiments described later, and are not intended to limit the technical scope. The objects, features and advantages disclosed in the present specification will become more apparent by reference to the following detailed description and the accompanying drawings.

It is sectional drawing seen from the top which shows the structure of the vehicle air conditioner of 1st Embodiment. It is the side view seen from the side which shows the structure of a vehicle air conditioner. It is a front view which shows a 2nd door. It is a bottom view showing the 2nd door. It is a block diagram which shows the structure in the attachment state of a 1st door and a 2nd door. It is a fragmentary sectional view showing the composition in the attachment state of the 1st door and the 2nd door. It is a schematic sectional view according to process of a mold for explaining a molding cycle. It is process-based schematic sectional drawing of the metal mold | die for demonstrating a molding cycle. FIG. 9 is a schematic cross-sectional view showing a cross section taken along line IX-IX of FIG. 8; It is process-based schematic sectional drawing of the metal mold | die for demonstrating a molding cycle. It is process-based schematic sectional drawing of the metal mold | die for demonstrating a molding cycle. It is a front view which shows the 2nd door of 2nd Embodiment. It is a block diagram which shows the structure in the attachment state of the 1st door of 2nd Embodiment, and a 2nd door. It is process-based schematic sectional drawing of the metal mold | die for demonstrating the molding cycle of 2nd Embodiment. It is process-based schematic sectional drawing of the metal mold | die for demonstrating the molding cycle of 3rd Embodiment. It is process-based schematic sectional drawing of the metal mold | die for demonstrating the molding cycle of 4th Embodiment.

Several embodiments will be described with reference to the drawings. In embodiments, functionally and / or structurally corresponding portions and / or associated portions may be provided with the same reference symbols, or reference symbols with different places of one hundred or more places. The description of the other embodiments can be referred to for the corresponding parts and / or parts to be associated.

First Embodiment In FIG. 1, a vehicle air conditioner 1 includes a fan unit 10 and an air conditioning unit 20 that adjusts the temperature of the air blown from the fan unit 10. The vehicle air conditioner 1 adjusts the temperature of the air blown by the blower unit 10 by the air conditioning unit 20, and supplies the air into the passenger compartment. Blower unit 10 is disposed on the left side of the vehicle near the front passenger seat side from the central portion of the lower part of the dashboard in the vehicle compartment. On the other hand, the air conditioning unit 20 is disposed at a substantially central portion in the left-right direction of the vehicle in the lower part of the dashboard in the vehicle compartment.

The blower unit 10 has a blower fan 11 which is a centrifugal multi-blade fan. The blower fan 11 is, for example, a sirocco fan. The blower fan 11 is disposed in the spiral scroll casing 12. The blower fan 11 is rotationally driven by an electric motor. The blowing air of the blowing fan 11 is sent along the spiral shape of the scroll casing 12 in the direction indicated by the arrow A1.

The suction port of the blower fan 11 is provided on the upper side of the vehicle. The suction port is provided with two suction ports, an inside air suction port and an outside air suction port. An inside / outside air switching door is provided between the blower fan 11 and the suction port. The inside / outside air switching door switches which one of the inside air intake and the outside air intake from which air is drawn.

The air conditioning unit 20 incorporates the evaporator 22 and the heater core 23 in the air conditioning case 21. The air conditioning case 21 is a resin molded article having a certain degree of elasticity and excellent in strength. As a material of the air conditioning case 21, polypropylene or the like can be used. The air conditioning case 21 is composed of a plurality of divided cases having divided surfaces in the vertical direction. The plurality of divided cases are integrally joined by fastening means such as a metal spring clip and a screw after housing devices such as the evaporator 22 and the heater core 23 to constitute the air conditioning case 21.

In FIG. 2, an air inlet 24 is disposed at the most forward side of the air conditioning case 21. The air inlet 24 is an opening through which air blown from the fan unit 10 flows. The air inlet 24 is connected to the air outlet of the scroll casing 12 of the fan unit 10. That is, the air inlet 24 is opened on the side of the air conditioning case 21 on the passenger seat side.

In the air conditioning case 21, an evaporator 22 is disposed immediately after the air inlet 24. The evaporator 22 is disposed to cross the inside of the air conditioning case 21 in a thin form in the longitudinal direction of the vehicle. The evaporator 22 cools the air by absorbing the latent heat of evaporation of the refrigerant of the refrigeration cycle from the surrounding air. The evaporator 22 is a so-called laminated type evaporator, in which a flat tube made by bonding two metal thin plates such as aluminum is laminated and intervened by interposing a corrugate fin. It is.

A heater core 23 is disposed on the downstream side of the air flow of the evaporator 22 so as to be inclined rearward of the vehicle. The heater core 23 is a heat exchanger that heats the cold air that has passed through the evaporator 22. The heater core 23 has engine cooling water, which is high-temperature hot water, flowing therein, and heats air using the hot water as a heat source. The heater core 23 is obtained by integrally laminating a flat tube formed by joining a thin metal plate such as aluminum in a flat shape by welding or the like with a corrugated fin interposed therebetween in a stacked manner.

In FIG. 1, the air passage inside the air conditioning case 21 is provided to extend in the longitudinal direction of the vehicle. An air passage inside the air conditioning case 21 is partitioned by a partition plate 27 in the left-right direction of the vehicle. In other words, the air passage is divided into a first air passage 25 located on the vehicle left side of the partition plate 27 and a second air passage 26 located on the vehicle right side of the partition plate 27. That is, the first air passage 25 is a passenger side air passage. The first air passage 25 is an air passage closer to the blower unit 10 than the second air passage 26. The second air passage 26 is a driver's seat side air passage. The second air passage 26 is an air passage farther from the blower unit 10 than the first air passage 25.

The partition plate 27 is continuously provided in the vehicle longitudinal direction from the downstream end of the evaporator 22 to the downstream wall surface of the air conditioning case 21. The partition plate 27 divides the first air passage 25 and the second air passage 26. The partition plate 27 has a cutout shape in order to avoid direct contact with the heater core 23 at the location where the heater core 23 is disposed. The partition plate 27 is made of resin such as polypropylene. The partition plate 27 may be formed integrally with the air conditioning case 21 instead of being provided as a separate part.

The heater core 23 is disposed to cross the first air passage 25 and the second air passage 26. The inside of the heater core 23 is partitioned at the same position as the partition plate 27 by the flat surface of the flat tube or the fin surface of the corrugated fin. That is, air can not pass between the first air passage 25 and the second air passage 26 by passing through the inside of the heater core 23.

In the first air passage 25, a first door 110 is provided between the evaporator 22 and the heater core 23. The first door 110 is a flat door that rotates about an axis to adjust the opening degree. The first door 110 is provided without gaps so as to cross the first air passage 25. Similarly to the first air passage 25 in the second air passage 26, a second door 120 is provided between the evaporator 22 and the heater core 23. The second door 120 is a flat door that rotates about an axis to adjust the opening degree. The second door 120 is provided without a gap so as to cross the second air passage 26.

The first door 110 includes a first rotation shaft portion 111. The second door 120 includes a second rotation shaft portion 121. The first rotation shaft portion 111 and the second rotation shaft portion 121 are aligned on the same straight line. In other words, the first rotation shaft portion 111 and the second rotation shaft portion 121 are coaxial rotation shafts. In other words, the first door 110 and the second door 120 are coaxial doors whose rotation axes are aligned on the same straight line. The first rotation shaft portion 111 is rotatably supported by an intermediate bearing portion 28 provided on the partition plate 27. The intermediate bearing portion 28 is located between the first door 110 and the second door 120.

The first rotation shaft portion 111 and the second rotation shaft portion 121 are coupled to the actuator mechanism 320. The actuator mechanism 320 has two drive sources, such as a servomotor, and drives each of the first rotation shaft portion 111 and the second rotation shaft portion 121 independently. The power may be transmitted between the

rotary shaft portions

111 and 121 and the actuator mechanism 320 via a link mechanism.

In FIG. 2, in the upper area of the heater core 23 in the first air passage 25 in the air conditioning case 21, a first cold air bypass passage 29 in which the air flows while bypassing the heater core 23 is formed. Similarly, in the upper region of the heater core 23 in the second air passage 26, a second cold air bypass passage 30 in which air flows by bypassing the heater core 23 is formed. The air passing through the cold

air bypass passages

29 and 30 is not heated by the heater core 23 and thus is in the state of cold air heat-exchanged with the evaporator 22.

In the air conditioning case 21, on the air downstream side of the heater core 23, a wall surface 33 facing the heater core 23 and extending in the vertical direction at a predetermined interval is formed. The wall surface 33 is integrally formed with the air conditioning case 21. The wall surface 33 forms, in the first air passage 25, a first hot air passage 34 directed upward from immediately after the heater core 23. Furthermore, in the second air passage 26, a second hot air passage 35 directed upward from immediately after the heater core 23 is formed by the wall surface 33.

On the downstream side of the first hot air passage 34, a first cold / warm air mixing space 36 which merges with the first cold air bypass passage 29 in the upper part of the heater core 23 is formed. On the downstream side of the second hot air passage 35, a second cold / warm air mixing space 37 which merges with the second cold air bypass passage 30 in the upper part of the heater core 23 is formed.

The first door 110 and the second door 120 are rotatable in the vertical direction of the vehicle. When the first door 110 is in the closed state, the first cold air bypass passage 29 is in the open state, and the air is not sent to the heater core 23. On the other hand, when the first door 110 is fully open, the first cold air bypass passage 29 is closed, and the wind is sent to the heater core 23. When the first door 110 is in the open state between the closed state and the fully open state, a part of the wind passes through the first cold air bypass passage 29 and the remaining wind is sent to the heater core 23. Similarly to the first door 110, the second door 120 changes and controls the ratio of the path through which the wind is sent according to the opening degree. That is, the first door 110 and the second door 120 are temperature adjusting means for adjusting the temperature of the blowing air by adjusting the amount of air passing through the cold

air bypass passages

29 and 30. In other words, the first door 110 and the second door 120 are air mix doors that adjust the mixing ratio of cold air and warm air.

A first defroster opening 38 is formed on the upper surface of the air conditioning case 21 corresponding to the first air passage 25. The temperature-controlled air from the first cold / warm air mixing space 36 flows into the first defroster opening 38. The conditioned air flowing into the first defroster opening 38 is blown out from the defroster outlet toward the window glass on the front of the vehicle through the defroster duct. A second defroster opening 39 is formed on the upper surface of the air conditioning case 21 corresponding to the second air passage 26. The temperature-controlled conditioned air from the second cold / warm air mixing space 37 flows into the second defroster opening 39. The conditioned air flowing into the second defroster opening 39 is blown out from the defroster outlet toward the window glass on the front of the vehicle through the defroster duct.

A first defroster door 130 a is provided upstream of the first defroster opening 38 for opening and closing the first defroster opening 38. The first defroster door 130a includes a cylindrical first rotary shaft portion 131a. A second defroster door 130 b is provided upstream of the second defroster opening 39 for opening and closing the second defroster opening 39. The second defroster door 130 b includes a cylindrical second rotary shaft portion 131 b.

The

defroster doors

130a and 130b are flat doors that rotate about an axis to adjust the opening degree. The

rotating shaft portions

131a and 131b of the

defroster doors

130a and 130b are arranged to be aligned on the same straight line in the left-right direction of the vehicle. In other words, the

defroster doors

130a, 130b are coaxial doors.

In FIG. 1, left and right face opening portions 43 to 52 are provided in a portion on the vehicle rear side of the upper surface portion of the air conditioning case 21. In the air conditioning case 21,

face openings

43, 44, 49, 50 are provided at the center side. The left and right

rear face openings

49, 50 are located closer to the center closer to the partition plate 27 than the

center face openings

43, 44. In the air conditioning case 21, side face openings 45 to 48 are provided on both sides of the center. In the air conditioning case 21, auxiliary

rear face openings

51 and 52 are provided behind the

rear face openings

49 and 50. The face openings 43 to 52 are openings that lead to a face duct that blows conditioned air to the upper body including the face of the occupant.

In FIG. 2, the air conditioning case 21 is provided with left and right foot openings 55, 56 at the rear side of the cold and warm air mixing spaces 36, 37. The foot openings 55, 56 are openings connected to a foot duct that blows conditioned air to the feet of the occupant.

Upstream of the face openings 43 to 52 and the foot openings 55, 56, foot

face switching doors

140a, 140b are provided corresponding to the

air passages

25, 26, respectively. The foot

face switching doors

140a and 140b are doors that switch which of the flow paths flowing to the face openings 43 to 52 and the flow paths flowing to the foot openings 55 and 56 flow the conditioned air.

The foot

face switching doors

140a and 140b are flat-shaped doors that rotate about an axis to adjust the opening degree. The foot

face switching doors

140a and 140b are respectively provided with

rotary shaft portions

141a and 141b serving as axes for rotational driving. The rotating shaft portion 141a is a cylindrical rotating shaft. The rotating shaft portion 141 b is a cylindrical rotating shaft. The cylindrical rotary shaft portion 141a is mounted on the vehicle air conditioner 1 in a state where the shaft is inserted into the cylindrical rotary shaft portion 141b. The rotating shaft portion 141a and the rotating shaft portion 141b are arranged in line in the same straight line along the vehicle left-right direction. That is, the foot

face switching doors

140a and 140b are coaxial doors.

In FIG. 3, the second door 120 includes a second rotation shaft portion 121, a second flat plate portion 122, and a seal portion 123. The second rotation shaft portion 121 is cylindrical. That is, the inside of the second rotation shaft portion 121 is hollow. The second rotary shaft portion 121 has an uneven shape formed on a cylindrical outer peripheral surface. In other words, the second rotation shaft portion 121 has a shape that varies in thickness depending on the portion. The second rotation shaft portion 121 corresponds to a cylindrical portion.

The second flat plate portion 122 is a substantially rectangular plate-like member. The second flat plate portion 122 is provided on the outer periphery of the second rotation shaft portion 121. The second flat plate portion 122 is provided in a region from one end of the second rotation shaft portion 121 to a position beyond the center of the second rotation shaft portion 121 in the longitudinal direction. The second rotation shaft portion 121 and the second flat plate portion 122 are an integral integral component.

The seal portion 123 is a thin plate member made of rubber. In other words, the seal portion 123 is a fin-like packing that covers a gap generated between the second rotation shaft portion 121 and another member such as the air conditioning case 21. The seal portion 123 maintains contact with the contact surface by being flexibly deformed. The seal portion 123 is provided at a position opposite to the second flat plate portion 122 with the second rotation shaft portion 121 interposed therebetween. The second rotation shaft portion 121 and the seal portion 123 are separate parts.

The second rotation shaft portion 121 is provided with a flange portion 124. The flange portion 124 protrudes outward in the radial direction of the central axis of the second rotation shaft portion 121. The flange portion 124 has a disk shape. The flange portion 124 is provided in the second rotation shaft portion 121 so that the end surface of the second flat plate portion 122 and the end surface of the flange portion 124 are aligned on the same plane.

The second rotation shaft portion 121 is provided with a through hole 125 on the side surface. The through hole 125 penetrates the inside and the outside of the second rotation shaft portion 121. The through hole 125 is provided near the flange portion 124. The through holes 125 are square openings.

In FIG. 4, the second door 120 is provided with two through holes 125. The two through holes 125 are provided side by side in the circumferential direction of the central axis of the second rotation shaft portion 121. That is, the two through holes 125 are provided at the same distance from the flange portion 124. The two through holes 125 are provided on the opposite side to the second flat plate portion 122 with the second rotation shaft portion 121 interposed therebetween.

The number of through holes 125 is not limited to two. That is, three or more through holes 125 may be provided. Alternatively, one through hole 125 extending in the circumferential direction may be provided. The plurality of through holes 125 may not be provided at positions aligned in the circumferential direction, but may be provided at positions displaced in the longitudinal direction of the second rotation shaft portion 121.

In FIG. 5, the first door 110 and the second door 120 are provided side by side in the axial direction with the partition plate 27 interposed therebetween. The cylindrical first rotary shaft portion 111 is in a state of being inserted into the cylindrical second rotary shaft portion 121. That is, the 1st door 110 and the 2nd door 120 are coaxial doors which exist in the position where the central axis of rotation drive is equal.

The first door 110 includes a first rotating shaft portion 111 and a first flat plate portion 112. The first rotation shaft portion 111 is cylindrical. The first flat plate portion 112 is a substantially rectangular plate-like member. The first flat plate portion 112 is provided on the outer periphery of the first rotation shaft portion 111.

The first door 110 is attached to the air conditioning case 21 by being held by the first bearing 118 and the intermediate bearing 28. That is, the first bearing portion 118 is held in contact with the first rotation shaft portion 111 in a state of partially covering the outer periphery of the first rotation shaft portion 111. The second door 120 is held by the second bearing portion 128 and attached to the air conditioning case 21. That is, the second bearing portion 128 is held in contact with the second rotation shaft portion 121 in a state of partially covering the outer periphery of the second rotation shaft portion 121. The first bearing portion 118 and the second bearing portion 128 are integrally provided in the air conditioning case 21. The second bearing portion 128 corresponds to a bearing portion.

The flange portion 124 and the second bearing portion 128 are in contact with each other. That is, the movement of the second rotary shaft portion 121 in the axial direction is restricted by the contact between the flange portion 124 and the second bearing portion 128. In other words, the contact between the flange portion 124 and the second bearing portion 128 prevents the second door 120 from being displaced in the axial direction.

In FIG. 6, the first rotation shaft portion 111 is inserted into the second rotation shaft portion 121. In other words, the second rotation shaft portion 121 is located radially outward of the first rotation shaft portion 111. The second rotation shaft portion 121 has a cylindrical shape with high coaxiality. That is, in the circular shape of the two end portions of the second rotation shaft portion 121, the central axes thereof substantially coincide with each other. In other words, the central axes of the two ends are not offset, and they have a straight cylindrical shape with no distortion inside.

The through hole 125 is surrounded by the second bearing 128. That is, the fluid such as air is unlikely to enter the through hole 125 from the outside. Furthermore, the second bearing portion 128 covers the through hole 125 continuously for one round in the circumferential direction of the second bearing portion 128. That is, even when the second door 120 is pivoted for opening and closing, the second bearing portion 128 always maintains the state in which the through hole 125 is covered from the outside.

Hereinafter, a method of manufacturing the second door 120 by injection molding will be described. In FIG. 7, the second door 120 is manufactured by injection molding using four molds of a first outer mold 71, a second outer mold 72, an inner mold 73, and a holding mold 74. The first outer mold 71 and the second outer mold 72 correspond to an outer mold.

The first outer mold 71 and the second outer mold 72 are in a positional relationship facing each other. The

outer molds

71 and 72 are molds that form the cylindrical outer side of the second rotary shaft portion 121. The first outer mold 71 is a cavity mold that does not move during injection molding. The first outer mold 71 is provided with a first recess 75 a on the surface facing the second outer mold 72. The first outer mold 71 includes a sprue 77 serving as a resin injection path and a gate 78 serving as a resin injection port. The second outer mold 72 is a core mold that moves during injection molding. The second outer mold 72 is provided with a second recess 75 b on the surface facing the first outer mold 71. The first recess 75a and the second recess 75b are provided at positions facing each other. The first recess 75 a and the second recess 75 b have a mold shape for forming the flange portion 124 of the second rotation shaft portion 121. The second outer mold 72 is provided with a second convex portion 172. The second convex portion 172 is provided so as to project on the surface of the second outer mold 72 facing the first outer mold 71. The second convex portion 172 has a mold shape for forming the through hole 125 in the second rotation shaft portion 121.

The inner mold 73 and the holding mold 74 are in a positional relationship facing each other in the axial direction of the rod portion 173. The inner mold 73 is a mold that forms the cylindrical inner side of the second rotation shaft portion 121. The inner mold 73 and the holding mold 74 are core molds that move during injection molding. The inner mold 73 is provided with a rod-like portion 173. The rod-like portion 173 is cylindrical. The rod-like portion 173 is provided so as to vertically project from the surface of the inner mold 73 opposed to the holding mold 74. The holding mold 74 is provided with a holding recess 174. The rod-like portion 173 and the holding recess 174 face each other.

The movable core molds 72 to 74 are moved closer to the first outer mold 71, which is a cavity mold fixed in position. More specifically, the second outer mold 72 is vertically moved upward to approach the first outer mold 71. The inner mold 73 is translated rightward to approach the first outer mold 71. The holding mold 74 is translated leftward to approach the first outer mold 71. By connecting the core molds which are movable molds 72 to 74 with pins, sliding movement of the core molds is simultaneously performed, and the core molds are simultaneously brought close to the cavity molds.

The moving direction of the molds 72 to 74 is not limited to the vertical direction or the horizontal direction, and may be moved in a free direction such as an oblique direction to approach the first outer mold 71. Also, the molds 72 to 74 may be connected by pins and interlocked, and may not be moved simultaneously but moved separately. That is, after the second outer mold 72 is brought close to the first outer mold 71, the inner mold 73 may be moved.

The process shown in FIG. 8 is a mold clamping process. In the mold clamping process, the four molds of the first outer mold 71, the second outer mold 72, the inner mold 73, and the holding mold 74 are held in contact and combined. In the mold in a clamped state, a cavity 76 is formed between the molds. The cavity 76 is a cavity corresponding to the shape of the second door 120. In the mold clamping process, pressure is applied from the outside so that the molds come into contact without any gap other than the hollow portion 76 being generated.

The tip end of the rod-like portion 173 is in a state of being inserted into the holding recess 174. In other words, the rod portion 173 is held by the holding recess 174 and positioned. The rod-like portion 173 is in contact with the second convex portion 172. The second convex portion 172 is provided on the side opposite to the side where the gate 78 is disposed with the rod portion 173 interposed therebetween. The rod-like portion 173 has a straight cylindrical shape with no distortion in a state where the tip end is inserted into the holding recess 174 and the side surface is in contact with the second convex portion 172. In other words, the rod-like portion 173 is not bent or bent.

In FIG. 9, a cavity 76 for forming the second door 120 is formed between the dies. The hollow portion 76 is a continuous hollow portion formed by integrally forming the second flat plate portion 122 and the second rotation shaft portion 121 of the second door 120. The first outer mold 71 is formed with a sprue 77 serving as a path for filling a resin. The cavity 76 and the sprue 77 are connected via the gate 78. The gate 78 is provided at a portion where the second flat plate portion 122 of the second door 120 is formed. The mold is in a state where the inside into which the resin flows is heated to a predetermined temperature.

The first convex portion 171 has a projecting shape which protrudes from a portion which is recessed to form the hollow portion 76 in the first outer mold 71. The first convex portion 171 is in contact with the rod-like portion 173 in a clamped state to support the rod-like portion 173. The contact surface between the first convex portion 171 and the rod-like portion 173 has a curved surface shape along the outer peripheral surface of the cylindrical rod-like portion 173. That is, the first convex portion 171 and the rod-like portion 173 are in contact not at a point but at a surface. The first convex portion 171 is provided not obliquely below the rod portion 173 but obliquely below. In other words, the first convex portion 171 is provided at a position farther from the gate 78 than the rod-like portion 173. That is, the first convex portion 171 suppresses the rod portion 173 from causing a positional deviation in the downward direction, which is the gravity direction. In other words, the bar-like portion 173 is prevented from being deformed in the direction away from the gate 78, such as displacement or bending. Furthermore, the first convex portion 171 suppresses the rod-like portion 173 from approaching the first outer mold 71 in the injection process as compared to the state of the mold clamping process.

The second convex portion 172 has a protruding shape which protrudes from a portion which is recessed to form the hollow portion 76 in the second outer mold 72. The second convex portion 172 is in contact with the rod-like portion 173 in a clamped state and supports the rod-like portion 173. The contact surface of the second convex portion 172 with the rod-like portion 173 has a curved shape along the outer circumferential surface of the cylindrical rod-like portion 173. That is, the second convex portion 172 and the rod-like portion 173 are in contact not at a point but at a surface. The second convex portion 172 is provided not obliquely below the rod portion 173 but obliquely below. In other words, the second convex portion 172 is provided at a position farther from the gate 78 than the rod-like portion 173. That is, the second convex portion 172 suppresses that the rod-like portion 173 causes positional deviation in the downward direction, which is the gravity direction. In other words, the bar-like portion 173 is prevented from being deformed in the direction away from the gate 78, such as displacement or warpage. Furthermore, the second convex portion 172 suppresses the rod-like portion 173 from approaching the second outer mold 72 in the injection process as compared to the state of the mold clamping process.

The first convex portion 171 and the second convex portion 172 are provided such that the contact portions between the

convex portions

171 and 172 and the rod-like portion 173 are arranged in the circumferential direction of the rod-like portion 173. The contact portion between the

convex portions

171 and 172 and the rod-like portion 173 is located not on the upper surface of the rod-like portion 173 which is a surface close to the gate 78 but on the lower surface of the rod-like portion 173 which is a surface far from the gate 78. In other words, the

convex portions

171 and 172 are in contact with the surface of the rod portion 173 opposite to the gate 78 and support the rod portion 173. The first convex portion 171 and the second convex portion 172 suppress the positional deviation of the rod portion 173 downward. In other words, the rod-like portion 173 is prevented from being displaced or deformed in the direction away from the gate 78. The first convex portion 171 and the second convex portion 172 suppress the positional deviation in the direction in which the rod-like portions 173 approach the

outer molds

71 and 72, respectively. That is, the first convex portion 171 and the second convex portion 172 suppress the positional deviation of the rod portion 173 in the horizontal direction. The first convex portion 171 and the second convex portion 172 correspond to a convex portion.

The convex part provided in the

outer side molds

71 and 72 is not limited to the case where it is provided in two places of the 1st convex part 171 and the 2nd convex part 172. FIG. That is, three or more convex portions may be provided. Alternatively, one protrusion extending in the circumferential direction of the rod-shaped portion 173 may be provided to suppress positional deviation of the rod-shaped portion 173 in the horizontal direction and the lower direction.

The process shown in FIG. 10 is an injection process. In the injection process, the resin heated to a high temperature and melted is injected and filled toward the cavity 76. That is, high temperature molten resin is injected from the sprue 77 and filled in the cavity 76 through the gate 78. The molten resin is injected and pushed out into the cavity 76 one after another from a position close to the gate 78 to move in the cavity 76. In other words, the molten resin gradually moves to a position away from the gate 78 by being injected. Since the inside of the mold is heated to a predetermined temperature, the molten resin can easily move in the cavity 76 while maintaining the low viscosity state.

The molten resin proceeds in the direction indicated by arrow B1 in the process of being injected and filled. That is, the molten resin applies an injection pressure to the rod portion 173 in a direction away from the gate 78. In other words, the rod portion 173 is applied with a force that is pushed downward from above by the injection pressure of the molten resin. Therefore, due to the injection pressure received from the molten resin, the rod-like portion 173 tends to be deformed in a downwardly curved shape.

However, a pressing force is applied to the rod-like portion 173 from the

projections

171 and 172 so as to resist the injection pressure. In other words, the pressing force of the

convex portions

171 and 172 provided on the side opposite to the gate 78 applies a force that pushes the rod portion 173 back from the lower side to the upper side. In other words, a pressing force is applied to the rod-like portion 173 in the direction indicated by the arrow C1 from the first protrusion 171, and a pressing force is applied from the second protrusion 172 in the direction indicated by the arrow C2. The direction indicated by the arrow C1 and the direction indicated by the arrow C2 are directions toward the central axis of the rod-like portion 173, respectively. For this reason, the rod-shaped portion 173 is pushed back by the

convex portions

171 and 172, and the bending and bending of the rod-shaped portion 173 are suppressed. That is, the rod-like portion 173 tends to maintain a straight cylindrical shape without deformation in the injection process.

After the molten resin is filled into the cavity 76 by the injection process, the filling of the molten resin is stopped and the mold is cooled. By cooling the mold, the resin is cooled and solidified to a temperature below the melting point. Thereby, the resin is solidified and the second door 120 is formed inside the mold.

The process shown in FIG. 11 is a mold opening process. In the mold opening process, the mold is opened and the second door 120 which is a resin molded product is taken out. That is, while releasing the contact between the inner mold 73 and the holding mold 74 and removing the rod-like portion 173 from the cylindrical second rotary shaft portion 121, the mold is moved by moving the second outer mold 72. Separate from each other. Thereby, the injection-molded second door 120 is removed from the mold and taken out.

According to the above-described embodiment, in the injection step, the inner mold 73 having the rod-like portion 173 pushes the pressing force for pushing back the inner mold 73 against the injection pressure pushed by the injection of the resin member. Receive from In other words, the rod-like portion 173 receives the pressing force from the

convex portions

171 and 172, so that the position and the shape of the rod-like portion 173 are prevented from being changed in the injection process as compared with the state of the mold clamping process. Therefore, the deformation of the inner mold 73 can be suppressed, and the second door 120 with high coaxiality can be stably manufactured. Therefore, air conditioning can be performed using a door for an air conditioner having a high degree of coaxiality. In other words, in the door for an air conditioner, the generation of abnormal noise due to the friction caused by the rotation of the door, the excessive operation force due to the abnormal load, and the poor opening adjustment are unlikely to occur.

The

protrusions

171 and 172 are in contact with the surface of the rod portion 173 opposite to the gate 78. In other words, therefore, the pressing force can be applied to the rod-like portion 173 so as to resist the injection pressure applied in the direction away from the gate 78. In other words, pressing force can be applied in a direction approaching the gate 78. Therefore, bending in a direction away from the gate 78 can be accurately suppressed. Moreover, the

convex parts

171 and 172 support the rod-like part 173 from the bottom. Therefore, a pressing force can be applied to the rod portion 173 so as to resist gravity. That is, it is possible to suppress the rod portion 173 from being deformed so as to bend downward in the gravity direction.

In the injection step, the inner mold 73 having the rod-like portion 173 receives a pressing force from the plurality of second convex portions 172. For this reason, the inner mold 73 disperses from the plurality of second convex portions 172 and receives a pressing force. Therefore, it is possible to prevent the pressing force from being concentrated on one place of the inner mold 73. That is, the deformation of the inner mold 73 can be suppressed more effectively.

The second convex portion 172 is provided side by side in the circumferential direction with respect to the inner mold 73 having the rod-like portion 173. Therefore, even if the direction in which the injection pressure is received changes in the middle, the inner mold 73 can be easily pushed back in a plurality of directions against the injection pressure. Therefore, the coaxiality of the 2nd rotating shaft part 121 can be raised stably.

The through hole 125 is surrounded by the second bearing portion 128. For this reason, it can suppress that a wind leaks through the through hole 125 in the state by which the 2nd door 120 was assembled | attached to the air-conditioning case 21. FIG. Therefore, it is possible to suppress the occurrence of problems such as a decrease in air volume due to a wind leak and a temperature decrease in air conditioning wind due to a wind leak, and to realize appropriate air conditioning as the vehicle air conditioner 1.

The highly coaxial second door 120 is disposed between the evaporator 22 and the heater core 23. That is, the second door 120 is disposed at a position where a large temperature difference occurs between cooling and heating. For this reason, even if the inner diameter of the second rotary shaft portion 121 changes due to temperature change, such as reduction of the inner diameter due to thermal contraction of the resin material due to temperature decrease or expansion of the inner diameter due to thermal expansion of the resin material due to temperature increase. , Easy to maintain high coaxiality. Therefore, it is hard to produce generation | occurrence | production of the noise by rubbing with the 1st door 110 and the 2nd door 120, and the defect of opening adjustment.

The air conditioner door manufactured using the manufacturing method described above is not limited to the second door 120. That is, the doors such as the defroster door 130, the foot face switching door 140, and the inside / outside air switching door may be manufactured using the above-described manufacturing method. In other words, the manufacturing method of the door for air conditioners mentioned above is widely applicable to the coaxial door which has a cylindrical axis. Moreover, as an air conditioner using this door, it is not restricted to vehicles. That is, the present invention can be widely applied to air conditioners not installed in vehicles such as home air conditioners and commercial air conditioners.

Second Embodiment This embodiment is a modification based on the preceding embodiment. In this embodiment, the through hole 225 is provided at the center of the second rotation shaft portion 221.

In FIG. 12, the second rotation shaft portion 221 has a cylindrical shape having a length twice or more that of the second flat plate portion 122. The second rotation shaft portion 221 is provided with a through hole 225 on the side surface. The through hole 225 is provided at the middle in the longitudinal direction of the second rotation shaft portion 221. In other words, the distance from the through hole 225 to the longitudinal center of the second rotation shaft 221 is smaller than the distance from the through hole 225 to the end of the second rotation shaft 221.

In FIG. 13, the second door 220 is held by the second bearing portion 128. That is, the second bearing portion 128 is in contact with the second rotation shaft portion 221 in a state where the outer periphery of the second rotation shaft portion 221 is covered over the entire circumference at the center in the longitudinal direction of the second rotation shaft portion 221. In other words, the second bearing portion 128 covers the through hole 225 from the outside.

In FIG. 14, the mold is in a clamped state. The first outer mold 71 is provided with a first recess 275 a on the surface facing the second outer mold 72. The second outer mold 72 is provided with a second recess 275 b on the surface facing the first outer mold 71. The first recess 275 a and the second recess 275 b are provided at mutually opposing positions. The second outer mold 72 is provided with a second convex portion 272. The second convex portion 272 is provided so as to protrude on the surface of the second outer mold 72 opposed to the first outer mold 71.

The rod-like portion 173 is in a state of being held and positioned by the holding recess 174. The rod-like portion 173 is in contact with the second convex portion 272. That is, the rod-like portion 173 is supported by the second outer mold 72 and the holding mold 74 at two points of the middle portion 273 and the tip portion. The rod-like portion 173 has a straight cylindrical shape with no distortion when the tip end is inserted into the holding recess 174 and the side surface is in contact with the second protrusion 272. That is, the rod-like portion 173 is not bent or bent.

The second convex portion 272 is provided so as to abut on an intermediate portion 273 positioned in the middle when one fixed end to the other fixed end of the rod-like portion 173 is divided into three equal parts. That is, the fixed end of the inner mold 73 which is in contact with the holding die 74 of the distance Wa from the fixed end of the rod portion 173 to the intermediate portion 273, the width Wb of the intermediate portion 273, and the intermediate portion 273 to the rod portion 173. The distances Wc up to are equal in size. The second convex portion 272 is in contact with the middle portion 273 particularly at a position near the center. The second convex portion 272 corresponds to a convex portion. The middle of the middle portion 273 is the middle portion, and the middle portion is a position where the distances from the fixed ends on both sides of the rod portion 173 are equal.

In the injection process, the rod-like portion 173 receives an injection pressure from the molten resin. As a result, the rod-like portion 173 is deformed into a warped shape by being pressed by the injection pressure. At this time, since the tip end portion of the rod-like portion 173 is held by the holding concave portion 174, the center of the rod-like portion 173 is the most susceptible to deformation and the amount of deformation being likely to be large. However, a pressing force is applied to the middle portion 273 including the center of the rod-like portion 173 from the second convex portion 272 so as to resist the injection pressure. Therefore, the rod-like portion 173 is pushed back from the second convex portion 272 in the vicinity of the center of the rod-like portion 173 where the amount of deformation is most likely to be large, and bending or bending of the rod-like portion 173 is suppressed. . Therefore, the rod-like portion 173 can easily maintain a straight cylindrical shape without deformation in the injection process.

According to the embodiment described above, the second convex portion 272 is in contact with the middle portion 273 of the rod-like portion 173 of the inner mold 73 having the rod-like portion 173 in the mold clamping process and the injection process. Therefore, large deformation of the rod portion 173 can be effectively suppressed as compared with the case where the second convex portion 272 is in contact with a position apart from the center of the rod portion 173 which is not the middle portion 273.

In the mold clamping process and the injection process, the second convex portion 272 is in contact with the central portion of the middle portion 273 of the rod portion 173. For this reason, it is possible to suppress the deformation at the pinpoint at the portion that is most susceptible to deformation. Therefore, large deformation of the rod-like portion 173 can be effectively suppressed as compared with the case where the second convex portion 272 is abutted to a position other than the central portion of the rod-like portion 173.

Third Embodiment This embodiment is a modification based on the preceding embodiment. In this embodiment, a plurality of convex portions 372 in contact with and supported by the rod-like portion 173 are provided in the axial direction of the rod-like portion 173.

In FIG. 15, the mold is in a clamped state. The second outer mold 72 includes a plurality of convex portions 372. The convex portion 372 is provided at a position in contact with an intermediate portion between the tip end portion and the central portion of the rod-like portion 173. The convex portion 372 is provided at a position in contact with an intermediate portion between the central portion of the rod-like portion 173 and the rising portion from the surface of the inner die 73 of the rod-like portion 173 facing the holding die 74. In other words, in the clamped state, the rod-like portion 173 is in contact with and supported by the plurality of convex portions 372 provided on the second outer mold 72 along the longitudinal direction of the rod-like portion 173. The second convex portion 272 and the convex portion 372 are provided on a straight line at substantially equal intervals.

According to the embodiment described above, the convex portions 372 that abut on and support the rod-shaped portion 173 are provided side by side at intervals in the axial direction of the rod-shaped portion 173. Therefore, in the injection process, the rod-like portion 173 receives the force against the injection pressure from the plurality of convex portions 372 in a dispersed manner. Therefore, the deformation of the rod-like portion 173 can be more effectively suppressed as compared with the case where the pressing force is concentrated in one place. In other words, it is possible to prevent the rod portion 173 from being broken or bent due to the effects of the injection pressure and the pressing force.

As the length of the rod-like portion 173 becomes longer, it becomes more difficult to maintain a straight cylindrical shape in the injection step, and it becomes more likely to be warped or deformed. Alternatively, as the diameter of the rod-like portion 173 becomes smaller, it becomes more difficult to maintain a straight cylindrical shape in the injection step, and it becomes easier to warp or bend and deform. Therefore, providing a plurality of convex portions 372 to suppress the deformation of the rod-like portion 173 in the injection process is particularly effective when the rod-like portion 173 is thin and long.

Fourth Embodiment This embodiment is a modification based on the preceding embodiment. In this embodiment, in the second outer mold 72, a second convex portion 172 and a convex portion 472 for supporting the rod-like portion 173 are provided side by side in the circumferential direction of the rod-like portion 173.

In FIG. 16, the convex portion 472 has a protruding shape which protrudes from a portion which is recessed to form the cavity portion 76 in the second outer mold 72. The convex portion 472 is in contact with the rod portion 173 in a clamped state and supports the rod portion 173. The contact surface of the convex portion 472 with the rod-like portion 173 has a curved shape along the outer circumferential surface of the cylindrical rod-like portion 173. That is, the convex portion 472 and the rod-like portion 173 are in contact not at a point but at a surface. The convex portion 472 is provided not diagonally below the bar portion 173 but obliquely above. In other words, the convex portion 472 is provided at a position facing the first convex portion 171. That is, the convex portion 472 prevents the rod-like portion 173 from being displaced upward. In other words, the rod-like portion 173 is sandwiched and held by the first convex portion 171 and the convex portion 472. In other words, occurrence of positional deviation or deformation in the direction in which the rod-like portion 173 approaches the gate 78 is suppressed. Further, the convex portion 472 suppresses the rod-like portion 173 from approaching the second outer mold 72 in the injection step as compared to the state of the mold clamping step.

The first convex portion 171, the second convex portion 172, and the convex portion 472 are provided in such a manner that the contact portions between the

convex portions

171, 172, 472 and the rod portion 173 are aligned in the circumferential direction of the rod portion 173. There is. The first convex portion 171 and the second convex portion 172 suppress the positional deviation of the rod-like portion 173 in the direction away from the gate 78 in the injection step. The convex portion 472 suppresses the occurrence of positional deviation in the direction in which the rod-like portion 173 approaches the gate 78 in the injection process. The first convex portion 171 suppresses the rod-like portion 173 from approaching the first outer mold 71 in the injection process as compared to the state of the mold clamping process. The second convex portion 172 and the convex portion 472 suppress the rod-like portion 173 from approaching the second outer mold 72 in the injection step as compared with the state of the mold clamping step. That is, the first convex portion 171, the second convex portion 172, and the convex portion 472 suppress the change in the position and the shape of the rod-like portion 173 in the injection step as compared with the state of the mold clamping step.

In the process of injection and filling of the resin, the molten resin may be filled in the cavity 76 to apply an injection pressure in a direction to separate the inner mold 73 from the

outer molds

71 and 72. At this time, the rod-like portion 173 tends to be deformed into a warped shape by the injection pressure received from the molten resin. However, a pressing force is applied to the rod-like portion 173 from the convex portion 472 so as to resist the injection pressure. In other words, the pressing force of the convex portion 472 applies a pressing force to the rod portion 173 so as to maintain the position and the shape of the state of the mold clamping process. In other words, the pressing force of the convex portion 472 is applied to the rod-like portion 173 in the direction toward the central axis of the rod-like portion 173. For this reason, the rod-like portion 173 is pushed back by the convex portion 472, and the bending and bending of the rod-like portion 173 are suppressed. That is, the rod-like portion 173 tends to maintain a straight cylindrical shape without deformation in the injection process.

Other Embodiments The disclosure in this specification is not limited to the illustrated embodiments. The disclosure includes the illustrated embodiments and variations based on them by those skilled in the art. For example, the disclosure is not limited to the combination of parts and / or elements shown in the embodiments. The disclosure can be implemented in various combinations. The disclosure can have additional parts that can be added to the embodiments. The disclosure includes those in which parts and / or elements of the embodiments have been omitted. The disclosure includes replacements or combinations of parts and / or elements between one embodiment and another embodiment. The disclosed technical scope is not limited to the description of the embodiments. Some technical scopes disclosed are indicated by the recitation of the claims, and should be understood to include all modifications within the meaning and scope equivalent to the recitation of the claims.

Claims

In a method of manufacturing an air conditioner door having a cylindrical portion (121),
The cylindrical portion has a rod-like inner mold (73) forming the inside of the cylindrical portion, and a convex portion (171, 172, 272, 372, 472) projecting toward the inner mold. And an outer mold (71, 72) that forms the outside of the mold is placed at a predetermined position, and a mold clamping step of combining the molds;
Injecting a resin member into a cavity (76) formed between the clamped inner mold and the outer mold;
In the mold clamping step, the inner mold and the convex portion of the outer mold are disposed in contact with each other,
In the injection step, the inner mold receives an injection pressure that is pushed by the injection of the resin member, and an air conditioning that receives a pressing force that pushes back the inner mold so as to resist the injection pressure. Method of manufacturing device door.
The outer mold includes a gate (78) which is an injection port for injecting the resin member into the hollow portion in the injection step;
2. The method according to claim 1, wherein, in the mold clamping step, the convex portion is in contact with a surface of the inner mold opposite to the gate. 3.
In the clamping step, the longitudinal tip of the inner mold is held in contact with the outer mold,
The method according to claim 1 or claim 2, wherein the convex portion (272) is in contact with an intermediate portion (273) in a longitudinal direction of the inner mold.
In the clamping step, the longitudinal tip of the inner mold is held in contact with the outer mold,
The method according to claim 3, wherein the convex portion (272) is in contact with a longitudinal central portion of the inner mold.
A plurality of the convex portions (171, 172, 272, 372, 472) are provided on the outer mold;
The method for manufacturing a door for an air conditioner according to any one of claims 1 to 4, wherein in the injection step, the inner mold receives the pressing force from a plurality of the convex portions.
The method according to claim 5, wherein the convex portion (171, 172, 472) is provided circumferentially with respect to the rod-like inner mold.
An air conditioning case (21) through which the air supplied into the passenger compartment passes inside;
A partition plate (27) for dividing the inside of the air conditioning case into a first air passage and a second air passage;
A first door (110) for opening and closing the first air passage;
A second door (120) for opening and closing the second air passage;
A first rotation shaft (111) for rotating the first door;
A through hole (125, 225) is provided on the side, and a cylindrical second rotary shaft (121, 221) for rotating the second door;
A method of manufacturing a vehicle air conditioner, wherein the second door is a door for an air conditioner manufactured by the method according to any one of claims 1 to 5,
A method of manufacturing a vehicle air conditioner, wherein the first door and the second door are axially aligned and attached to the air conditioning case with the first rotation shaft portion inserted in the second rotation shaft portion.
The air conditioning case includes a bearing (128) for holding the second rotating shaft.
The method according to claim 7, wherein the second door is attached to the air conditioning case such that the bearing portion covers the periphery of the through hole.