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JP4432090B2 - Multi-molded body - Google Patents
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JP4432090B2 - Multi-molded body - Google Patents

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JP4432090B2
JP4432090B2 JP2007173867A JP2007173867A JP4432090B2 JP 4432090 B2 JP4432090 B2 JP 4432090B2 JP 2007173867 A JP2007173867 A JP 2007173867A JP 2007173867 A JP2007173867 A JP 2007173867A JP 4432090 B2 JP4432090 B2 JP 4432090B2
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molded body
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JP2007245733A (en
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尚 鈴木
洋介 深川
宏治 關
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Azbil Corp
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Description

本発明は、低次の成形体の外側に熱可塑性樹脂を一体化形成した多次成形体に関する。   The present invention relates to a multi-order molded body in which a thermoplastic resin is integrally formed on the outside of a low-order molded body.

低次の成形体の外部に熱可塑性樹脂を一体化成形した多次成形体、例えば、図16に示すように低次の成形体(以下「一次成形体」という)1の上面1aと前部下面1bとに跨って熱可塑性樹脂としての二次成形体2により覆って多次成形体3を形成する場合、図17に示すように一次成形体1の両側部に夫々上端が上面1aに、下端が下面1bに開口する溝1cを設け、図18(a)に示すように金型3の各溝1cと対向して設けたゲート3gから溶融した熱可塑性樹脂を加圧注入して、一次成形体1の上面1aと前部下面1bとを上板2aと下板2bで覆うと共に各溝部1cにおける側部2cにより連設する。このようにして一次成形体1に二次成形体2をインサート成形する。   A multi-order molded body in which a thermoplastic resin is integrally molded outside the lower-order molded body, for example, an upper surface 1a and a front portion of a lower-order molded body (hereinafter referred to as “primary molded body”) 1 as shown in FIG. When the multi-molded product 3 is formed by covering with the secondary molded product 2 as a thermoplastic resin across the lower surface 1b, the upper ends are respectively on the upper surface 1a on both sides of the primary molded product 1 as shown in FIG. A groove 1c having a lower end opened on the lower surface 1b is provided, and a molten thermoplastic resin is injected under pressure from a gate 3g provided opposite to each groove 1c of the mold 3 as shown in FIG. The upper surface 1a and the front lower surface 1b of the molded body 1 are covered with the upper plate 2a and the lower plate 2b, and are continuously provided by the side portions 2c in the respective groove portions 1c. In this way, the secondary molded body 2 is insert-molded into the primary molded body 1.

上述したインサート成形により形成される多次成形体において二次成形体2の一次成形体1の上面1aを覆う上板2aと前部下面1bを覆う下板2bとの板厚が大きく異なる場合、例えば、上板2aに比して下板2bの板厚が薄い場合、図18(a)に示すように金型3と一次成形体1の上面1aとにより画成される空間(隙間)G1と、金型3と前部下面1bとにより画成される空間(隙間)G2とが大きく異なる。   When the plate thickness of the upper plate 2a covering the upper surface 1a of the primary molded body 1 of the secondary molded body 2 and the lower plate 2b covering the front lower surface 1b in the multi-molded body formed by the insert molding described above is greatly different, For example, when the plate thickness of the lower plate 2b is thinner than the upper plate 2a, a space (gap) G1 defined by the mold 3 and the upper surface 1a of the primary molded body 1 as shown in FIG. And a space (gap) G2 defined by the mold 3 and the front lower surface 1b is greatly different.

このため、図18(a),(b)に示すようにゲート3gから斜線で示す二次成形用の熱可塑性樹脂を充填すると、流動抵抗の違いにより空間G1側に積極的に充填が行われ、空間G2側には充填され難いという現象が発生し、下板2bが成形され難くなる。これは、充填する樹脂の流れ易さは、成形すべき板厚(樹脂の流れ込む隙間)の4乗に比例するためである。また上板2aと下板2bの板厚によっては、樹脂の流動抵抗のバランスが崩れて金型3全体に樹脂が廻ることなく冷却固化し、一次成形体の変形、この変形に伴う流路狭化により成形品の一部が欠ける所謂ショートモールドが発生する。更に複雑な作用によるショートモールドの例としては、同図(c)に示すように、先ず肉厚の大きい上板2a部分が薄肉の下板2bより先に充填が進み完了し、更に射出充填が進むにつれて上板2aは過充填となり、樹脂内圧が崩れる。その結果、一次成形体1は薄肉部の下板2b方向に変形し、下板2bの肉厚は更に薄くなってショートモールド2dが発生する。   For this reason, as shown in FIGS. 18A and 18B, when the thermoplastic resin for secondary molding indicated by hatching from the gate 3g is filled, the space G1 is positively filled due to the difference in flow resistance. The phenomenon that it is difficult to fill the space G2 occurs, and the lower plate 2b is difficult to be molded. This is because the ease of flow of the resin to be filled is proportional to the fourth power of the plate thickness (gap into which the resin flows) to be molded. Further, depending on the plate thickness of the upper plate 2a and the lower plate 2b, the balance of the flow resistance of the resin is lost, and the resin is cooled and solidified without the resin turning around the entire mold 3. As a result, a so-called short mold in which a part of the molded product is missing occurs. As an example of a short mold having a more complicated action, as shown in FIG. 2C, first, the filling of the upper plate 2a having a large wall thickness is completed before the lower plate 2b of the thin wall, and injection filling is further performed. As it progresses, the upper plate 2a becomes overfilled and the internal pressure of the resin collapses. As a result, the primary molded body 1 is deformed in the direction of the lower plate 2b of the thin portion, and the thickness of the lower plate 2b is further reduced to generate the short mold 2d.

更に図18に示す空間G1及びG2のように偏肉がある場合には、薄肉の空間G2側の金型壁面にゲート(図示せず)を形成し、先ず薄肉部への樹脂充填がなされた後で厚肉部G1へ樹脂が到着して充填されるように構成することも可能である。しかしこのときは空間G2側の成形面にゲート痕が残るので、この面に平面性・平滑性が要求されるような用途(例えば、後述するセンサの検出部)には適用することができない。   Further, when there is uneven thickness as in the spaces G1 and G2 shown in FIG. 18, a gate (not shown) was formed on the mold wall surface on the thin space G2 side, and the thin portion was first filled with resin. It is also possible to configure so that the resin arrives and fills the thick part G1 later. However, at this time, a gate mark remains on the molding surface on the space G2 side, and thus cannot be applied to an application (for example, a sensor detection unit described later) in which planarity and smoothness are required on this surface.

また下板2bを充填するために充填圧力を増加させると、一次成形体1が柔らかく強度の弱い樹脂による成形体である場合には、同図(d)に示すように上板2aや側部2cが充填過剰となり、一次成形体1が変形したり破壊されることがある。またゲート3gの位置を板厚の薄い下板2b側(空間G2側)に近づけても、上板2aと下板2bとのバランスを取る効果はあまり期待することができない。更にゲートの位置やゲート径の変更は、金型の改修が困難であり、且つ発生する費用も多大となる。また金型の構造的に変更できない場合も多い等多くの問題がある。   When the filling pressure is increased to fill the lower plate 2b, if the primary molded body 1 is a molded body made of a soft and weak resin, the upper plate 2a or the side portion is formed as shown in FIG. 2c becomes overfilled, and the primary molded body 1 may be deformed or destroyed. Further, even if the position of the gate 3g is brought closer to the thin plate 2b side (space G2 side), the effect of balancing the upper plate 2a and the lower plate 2b cannot be expected so much. Furthermore, if the gate position or the gate diameter is changed, it is difficult to repair the metal mold, and the generated cost increases. In addition, there are many problems such as many cases where the structure of the mold cannot be changed.

これを解決するために、樹脂の流路を構成する金型壁面に突起を設け、溶融樹脂に対し流体抵抗を与えて偏肉空間への充填バランスを調節する方法を考案したが、成型品を金型から取り出す際に突起が邪魔になって取り出し作業に手間取ること及び成形体の外観に凹部が形成されてしまうことから、製品への適用に制約が生じることが分かった。
本発明は上述の点に鑑みてなされたもので、金型のゲート位置やゲート形状を改修することなく溶融樹脂の流動状体を調節して低次の成形体の外側に設けられる熱可塑性樹脂をショートモールド等の問題を招来することなく精度良く形成した多次成形体を提供することを目的とする。
In order to solve this, a method has been devised in which protrusions are provided on the mold wall surface constituting the resin flow path and fluid resistance is given to the molten resin to adjust the filling balance to the uneven thickness space. It has been found that there is a restriction in the application to the product because the protrusions obstruct the removal from the mold and troublesome removal work and a concave portion is formed in the appearance of the molded body.
The present invention has been made in view of the above points, and is a thermoplastic resin that is provided on the outside of a lower-order molded body by adjusting the fluidized body of the molten resin without modifying the gate position and gate shape of the mold. An object of the present invention is to provide a multi-molded product that is formed with high accuracy without incurring problems such as short molding.

上記目的を達成するために請求項1に記載の多次成形体は、低次の成形体の外側に熱可塑性樹脂を一体化形成したものであって、前記熱可塑性樹脂はその表面に少なくとも2つのゲート痕を有すると共に、1つのゲート痕から他のゲート痕に至る間のそれぞれにウェルドを有し、
特に前記低次の成形体は、前記熱可塑性樹脂の層にて全体が覆われる突出部をその表面に備え、この突出部は少なくとも上記熱可塑性樹脂の1つのゲート痕から前記ウェルドの1つに至る間に位置することを特徴としている。
In order to achieve the above object, the multi-molded article according to claim 1 is obtained by integrally forming a thermoplastic resin on the outside of a low-order molded article, and the thermoplastic resin has at least 2 on the surface thereof. Having one gate trace and a weld between each gate trace and the other gate trace,
Especially the lower order of the compact is provided with a protrusion whole in the layer of the thermoplastic resin is covered on the surface thereof, said one of the weld from one gate mark of the projecting portion is at least the thermoplastic resin It is characterized by being located everywhere.

また請求項2に記載の多次形成体は、低次の成形体の外側に熱可塑性樹脂を一体化形成したものであって、前記熱可塑性樹脂はその表面に少なくとも2つのゲート痕を有すると共に、1つのゲート痕から他のゲート痕に至る間のそれぞれにウェルドを有し、
特に前記熱可塑性樹脂が互いに肉厚の異なる部分を有し、また前記ウェルドは前記熱可塑性樹脂の肉厚の厚い部分および肉厚の薄い部分のいずれにも位置しており、そして前記低次の成形体は前記熱可塑性樹脂の層にて全体が覆われる突出部をその表面に備え、この突出部は少なくとも前記ゲート痕の1つから前記肉厚の厚い部分のウェルドに至る間に位置することを特徴としている。
Further, the multi-form product according to claim 2 is obtained by integrally forming a thermoplastic resin on the outside of a low-order molded product, and the thermoplastic resin has at least two gate marks on the surface thereof. Each has a weld between one gate mark and another gate mark,
In particular, the thermoplastic resin has portions with different thicknesses, and the weld is located in both the thick and thin portions of the thermoplastic resin, and the lower order The molded body is provided with a protrusion on its surface that is entirely covered with the thermoplastic resin layer, and the protrusion is located at least from one of the gate marks to the weld of the thick part. It is characterized by.

また請求項3に記載の多次成形体は、表面に露出した電子部品を有する低次の成形体の外側に熱可塑性樹脂を一体化形成したものであって、前記熱可塑性樹脂はその表面に少なくとも2つのゲート痕を有すると共に、1つのゲート痕から他のゲート痕に至る間のそれぞれにウェルドを有し、
特に前記低次の成形体は前記熱可塑性樹脂の層にて全体が覆われる突出部をその表面に備え、この突出部は少なくとも上記熱可塑性樹脂の1つのゲート痕からウェルドの1つに至る間に位置し、また前記ウェルドは前記電子部品を避けた位置にあることを特徴としている。
Further, the multi-molded product according to claim 3 is obtained by integrally forming a thermoplastic resin on the outside of a low-order molded product having an electronic component exposed on the surface, and the thermoplastic resin is formed on the surface. and having at least two gate mark, has a weld respectively between extending from one gate mark on the other gate mark,
Especially during the lower order of the compact is provided with a protrusion whole in the layer of the thermoplastic resin is covered on its surface, the protrusion extending into one of the weld from one gate mark of at least the thermoplastic resin And the weld is located at a position avoiding the electronic component.

上記構成の多次成形体によれば、低次の成形体の外部を覆う熱可塑性樹脂層は、前記低次の成形体の表面に設けられた突出部により流動抵抗を受けて充填率が変化して厚みが調節される。これにより、例えば低次の成形体の外部を覆う熱可塑性樹脂層の部分的に異なる厚み部分がそれぞれ精度よく成形される。
特に熱可塑性樹脂の充填バランスが確保され、前記低次の成形体の表面を覆う樹脂層の厚みを調節することができ、部分的に厚みの異なる樹脂層を精度よく成形することができる。
According to the multi-molded article having the above-described configuration, the thermoplastic resin layer covering the outside of the low-order molded body is subjected to flow resistance by the protrusion provided on the surface of the low-order molded body, and the filling rate changes. Then the thickness is adjusted. Thereby, for example, partially different thickness portions of the thermoplastic resin layer covering the outside of the low-order molded body are each accurately molded.
In particular, the filling balance of the thermoplastic resin is ensured, the thickness of the resin layer covering the surface of the low-order molded body can be adjusted, and resin layers having partially different thicknesses can be molded with high accuracy.

以下図面を参照して本発明の実施の形態について説明する。
図1は本発明に係る多次成形体の第1の実施形態を示している。多次成形体4は、略直方体形状をなし、低次成形体(以下「一次成形体」という)5の上面5aと前部下面5bとが二次成形体2の上板2aと下板2bとにより覆われ、上板2aと下板2bの両側部が側板2cにより連設されている。上板2aの板厚Tは下板2bの板厚tよりも厚く(T>t)成形されている。
Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 shows a first embodiment of a multi-molded product according to the present invention. The multi-order molded body 4 has a substantially rectangular parallelepiped shape, and an upper surface 5a and a front lower surface 5b of a lower-order molded body (hereinafter referred to as “primary molded body”) 5 are an upper plate 2a and a lower plate 2b of the secondary molded body 2. The both sides of the upper plate 2a and the lower plate 2b are connected by the side plate 2c. The plate thickness T of the upper plate 2a is formed to be thicker (T> t) than the plate thickness t of the lower plate 2b.

図2に示すように一次成形体5は、前部下面5bが後部下面5b’よりも前記した板2bの板厚tだけ低く形成されており、両側部の略中央に夫々上端が上面5aに、下端が前部下面5bに開口する溝5c,5cが設けられている。これらの溝5cは、二次成形体2を形成する溶融する熱可塑性樹脂の流路とされ、断面形状が一定とされている。そして図2及び図3に示すように各溝5cの上面5a側に開口する上端には、突出部としての凸部5dが設けられている。この凸部5dは、樹脂の流路としての溝5cの堰とされ、当該溝5cを上面5a側に流れる溶融樹脂の流量を制御する。即ち、凸部5dは、二次成形体2を成形する際に熱可塑性樹脂が過充填になると思われる流路に設けられている。本実施の形態の場合、図1に示すように二次成形体2は、上板2aの板厚Tが下板2bの板厚tよりも厚いため、溝5cの上端(上面5a側)に設けられている。   As shown in FIG. 2, the primary molded body 5 has a front lower surface 5b formed lower than the rear lower surface 5b ′ by the plate thickness t of the plate 2b, and has upper ends on the upper surface 5a at approximately the center of both sides. , Grooves 5c and 5c having lower ends opened in the front lower surface 5b are provided. These grooves 5c are flow paths of the thermoplastic resin that forms the secondary molded body 2, and have a constant cross-sectional shape. As shown in FIGS. 2 and 3, a convex portion 5d as a protruding portion is provided at the upper end of each groove 5c that opens to the upper surface 5a side. The convex portion 5d serves as a weir of a groove 5c serving as a resin flow path, and controls the flow rate of the molten resin flowing through the groove 5c toward the upper surface 5a. That is, the convex part 5d is provided in the flow path which is considered to be overfilled with the thermoplastic resin when the secondary molded body 2 is molded. In the case of the present embodiment, as shown in FIG. 1, the secondary molded body 2 has a thickness T of the upper plate 2a larger than a thickness t of the lower plate 2b. Is provided.

溝5cの凸部5dは、一次成形体5を形成する金型(図示せず)の前記溝5cを成形する凸条部に凹部を設けることで形成される。そこで、前記金型の凸条部に始めは僅かな凹部(小さな凹部)を作ることにより、一次成形体5の溝5cの底面に僅かに凸部(小さな凸部)を作る。そして、二次成形体2の樹脂の流れの変化を確認しながら、徐々に前記凹部を削り込んで凸部を大きくしていき、最も良好な充填バランスを確立する。これにより溶融樹脂の流動状体の調節を容易に行うことができる。この方法によれば、金型に凹み加工を進めていくだけであるため、加工が極めて容易であり、加工費用の発生が少なくて済む。また金型の溶融樹脂を射出するゲート位置、ゲート径、ゲート点数等は、充填バランスやウェルドの発生位置等を考慮して設定される。   The convex portion 5d of the groove 5c is formed by providing a concave portion on the convex strip portion that molds the groove 5c of a mold (not shown) that forms the primary molded body 5. Therefore, a slight convex portion (small convex portion) is formed on the bottom surface of the groove 5c of the primary molded body 5 by making a small concave portion (small concave portion) at the beginning of the convex strip portion of the mold. Then, while confirming the change in the resin flow of the secondary molded body 2, the concave portions are gradually cut to enlarge the convex portions, thereby establishing the best filling balance. As a result, the fluidized body of the molten resin can be easily adjusted. According to this method, since only the dent processing is advanced to the mold, the processing is extremely easy and the generation of processing costs can be reduced. Further, the gate position, the gate diameter, the number of gate points, etc. for injecting the molten resin of the mold are set in consideration of the filling balance, the weld generation position, and the like.

一次成形体5の外側に二次成形体2を成形する場合、図4に示すように金型3に一次成形体5を収納する。金型3と一次成形体5の上面5aとにより高さTの上部空間(隙間)G1が、金型3と前部下面5bとにより高さtの下部空間(隙間)G2が画成される。そして金型3のゲート3g,3gから溶融した熱可塑性樹脂を溝5c,5cにそれぞれ加圧注入する。各溝5cに注入された前記樹脂は、当該溝5c内を上・下に向かって流れ、空間G1,G2に充填される。溝5cを上方に向かって流れる前記溶融樹脂は、凸部5dにより流動抵抗を受けて流量が調節され、上下の空間G1,G2(偏肉厚部分)への前記溶融樹脂の充填バランスが確保される。これにより二次成形体2の上板2aおよび下板2bが所定の板厚T,tに正確に成形される。更に充填バランスが保もたれることで、ショートモールドが回避される。   When the secondary molded body 2 is molded outside the primary molded body 5, the primary molded body 5 is accommodated in the mold 3 as shown in FIG. 4. An upper space (gap) G1 having a height T is defined by the mold 3 and the upper surface 5a of the primary molded body 5, and a lower space (gap) G2 having a height t is defined by the mold 3 and the front lower surface 5b. . Then, molten thermoplastic resin is injected into the grooves 5c and 5c from the gates 3g and 3g of the mold 3, respectively. The resin injected into each groove 5c flows upward and downward in the groove 5c and fills the spaces G1 and G2. The molten resin flowing upward in the groove 5c is subjected to flow resistance by the convex portion 5d and the flow rate is adjusted, and the filling balance of the molten resin into the upper and lower spaces G1, G2 (uneven thickness portions) is ensured. The As a result, the upper plate 2a and the lower plate 2b of the secondary molded body 2 are accurately formed to a predetermined plate thickness T, t. Furthermore, a short mold can be avoided by maintaining the filling balance.

またこの製造方法により、従来は成形ができないと考えられているような充填バランスの悪い形状や、一次成形体として柔らかく強度の弱い樹脂成形体を使用することも可能となる。更に金型のゲート位置や形状では対処することができないような成形体、例えば溶融樹脂の流路の偏肉厚部の成形等も可能となる。
図5は本発明に係る多次成形体の第2の実施形態を示している。第1の実施形態において二次成形体2の樹脂の流路としての一次成形体5の溝5cの深さが一定であっても、断面形状や両端の溝幅が異なる場合における熱可塑性樹脂の充填バランスを確保するようにしたものである。一次成形体6の溝6cは、底面6eが開口端よりも狭く両側面がテーパ状に拡開して断面形状が台形をなし、更に一側開口端6caの溝幅がWa,wa、他側開口端6cbの溝幅がWb(<Wa),wb(<wa)とされている。そして溝6の、例えば底面6eの開口端6ca側寄りに適宜の大きさ及び形状の凸部6dが形成されている。これにより溝6cを流れる溶融樹脂の流量が調節されて、開口端6ca,6cbから充填部に流れ出る樹脂の充填バランスを確保する。尚、凸部6dは、溝6cの底面に限るものではなく側面に設けてもよい。勿論、金型のゲートGの位置、ゲート径、ゲート点数等は、前述したように充填バランスやウェルドの発生位置等を考慮して設定されている。
In addition, this manufacturing method makes it possible to use a shape with poor filling balance, which is conventionally considered to be impossible to mold, or a soft and weak resin molded body as a primary molded body. Further, it is possible to form a molded body that cannot be dealt with by the gate position and shape of the mold, for example, molding an uneven thickness portion of the flow path of the molten resin.
FIG. 5 shows a second embodiment of the multi-molded product according to the present invention. In the first embodiment, even when the depth of the groove 5c of the primary molded body 5 as the resin flow path of the secondary molded body 2 is constant, the thermoplastic resin in the case where the cross-sectional shape and the groove width at both ends are different. The filling balance is ensured. The groove 6c of the primary molded body 6 has a bottom surface 6e that is narrower than the opening end, and both side surfaces expand in a taper shape to form a trapezoidal cross section. Further, the groove width of the one side opening end 6ca is Wa, wa, the other side The groove widths of the open end 6cb are Wb (<Wa) and wb (<wa). A convex portion 6d having an appropriate size and shape is formed in the groove 6, for example, closer to the opening end 6ca side of the bottom surface 6e. As a result, the flow rate of the molten resin flowing through the groove 6c is adjusted, and the filling balance of the resin flowing out from the opening ends 6ca and 6cb to the filling portion is ensured. The convex portion 6d is not limited to the bottom surface of the groove 6c but may be provided on the side surface. Of course, the position of the gate G of the mold, the gate diameter, the number of gate points, and the like are set in consideration of the filling balance, the weld generation position, and the like as described above.

図6は本発明に係る多次成形体の第3の実施形態を示している。この実施形態は金型3の底部3Bの温度を上部3Aの温度よりも低くする必要のある、例えば底部3Bに一次成形体7の熱に弱い部品が接触するような場合における充填バランスを確保するようにしたものである。この場合、二次成形体2の上板2aの板厚Tと下板2bの板厚tとが同じ板厚(T=t)であっても、金型温度の低い底部3B方向への樹脂の流れが悪くなる。そこで一次成形体7の溶融樹脂流路としての溝7cの一部例えば底面に金型温度の高い上部3A側に適宜の大きさ及び形状の凸部7dを設けて二次成形体の充填バランスを確保するようにしている。尚、凸部7dについては、溝7cの底面に限るものではなく側面に設けても良い。   FIG. 6 shows a third embodiment of the multi-molded product according to the present invention. In this embodiment, it is necessary to make the temperature of the bottom part 3B of the mold 3 lower than the temperature of the upper part 3A. For example, a filling balance is ensured in the case where a part vulnerable to heat of the primary molded body 7 comes into contact with the bottom part 3B. It is what I did. In this case, even if the plate thickness T of the upper plate 2a of the secondary molded body 2 and the plate thickness t of the lower plate 2b are the same plate thickness (T = t), the resin in the direction of the bottom 3B where the mold temperature is low. The flow becomes worse. Therefore, a convex portion 7d having an appropriate size and shape is provided on a part of the groove 7c as a molten resin flow path of the primary molded body 7, for example, on the upper surface 3A side where the mold temperature is high, so that the filling balance of the secondary molded body is achieved. I try to secure it. The convex portion 7d is not limited to the bottom surface of the groove 7c but may be provided on the side surface.

図7は本発明の第4の実施形態を示し、第1乃至第3の実施形態の場合と反対に一次成形体を二次成形体で覆う際の熱可塑性樹脂の充填バランスを崩して、ウェルド(樹脂の最終結合点)位置を変更するようにしたものである。図7において例えば、一次成形体8に上面8aと接する、或いは上面8aと同一面をなすように電気部品9が含まれている場合、当該電気部品9の付近にウェルドが存在すると耐水性や強度が低下する虞があるために好ましくない。そこで、一次成形体8の溶融樹脂流路としての溝8c、8cの何れか一方の溝8cの一部例えば、底部に適宜の大きさ及び形状の凸部8dを設けて上面8a側と下面8b側に流れる樹脂の充填バランスを崩し、上面8aと下面8bとを覆う上板2aおよび下面2bに形成されるウェルド2aw、2bwの位置を変更して電気部品9から離すようにしたものである。金型3のゲート3gの位置、ゲート径、ゲート点数等は、前述したように充填バランスやウェルド2aw、2bwの発生位置等を考慮して設定されている。これにより、前記電気部品9に対する耐水性や強度を確保することができる。尚、凸部8dは、溝8cの底面に限るものではなく側面に設けても良い。   FIG. 7 shows a fourth embodiment of the present invention. In contrast to the first to third embodiments, the filling balance of the thermoplastic resin when the primary molded body is covered with the secondary molded body is broken, and the weld is (Final bonding point of resin) The position is changed. In FIG. 7, for example, when an electrical component 9 is included in the primary molded body 8 so as to be in contact with the upper surface 8a or to be flush with the upper surface 8a, the presence of welds in the vicinity of the electrical component 9 can improve water resistance and strength. Is not preferable because there is a risk of lowering. Therefore, a part of one of the grooves 8c as the molten resin flow path of the primary molded body 8 is provided, for example, a convex portion 8d having an appropriate size and shape at the bottom, and the upper surface 8a side and the lower surface 8b. The balance of the resin flowing to the side is destroyed, and the positions of the welds 2aw and 2bw formed on the upper plate 2a and the lower surface 2b covering the upper surface 8a and the lower surface 8b are changed to be separated from the electrical component 9. As described above, the position of the gate 3g, the gate diameter, the number of gate points, and the like of the mold 3 are set in consideration of the filling balance, the generation positions of the welds 2aw and 2bw, and the like. Thereby, the water resistance and intensity | strength with respect to the said electrical component 9 are securable. The convex portion 8d is not limited to the bottom surface of the groove 8c but may be provided on the side surface.

次に、本発明に係る多次成型体の第5の実施形態を、図8乃至図15を参照して説明する。図8は近接センサの斜視図、図9は図8に示す近接センサの一次成形体の斜視図、図10は、図2に示す近接センサの一次成形体を覆う二次成形体の斜視図である。尚、図10に示す二次成形体は、形状を判り易くするために図8に示す近接センサにおいて図9に示す一次成形体を取り除いた状態を示している。   Next, a fifth embodiment of the multi-molded product according to the present invention will be described with reference to FIGS. 8 is a perspective view of the proximity sensor, FIG. 9 is a perspective view of a primary molded body of the proximity sensor shown in FIG. 8, and FIG. 10 is a perspective view of a secondary molded body covering the primary molded body of the proximity sensor shown in FIG. is there. The secondary molded body shown in FIG. 10 shows a state in which the primary molded body shown in FIG. 9 is removed from the proximity sensor shown in FIG. 8 in order to make the shape easy to understand.

図8乃至図10に示すように近接センサ(樹脂成形体)10は、近接センサ本体としての一次成形体(樹脂成形体)11、この一次成形体11を覆う外殻としての二次成形体(樹脂成形体)12及び電線13から成る。成形体12の上板12aは一次成形体11の上面11aを覆い、下板12bは前部下面11bを覆う。そして上板12aの板厚Tは、例えば1mm、下面12bの板厚tは上板12aよりも薄く、例えば0.5mmに設定されている。   As shown in FIGS. 8 to 10, the proximity sensor (resin molded body) 10 includes a primary molded body (resin molded body) 11 as a proximity sensor body and a secondary molded body (outer shell covering the primary molded body 11). Resin molded body) 12 and electric wires 13. The upper plate 12a of the molded body 12 covers the upper surface 11a of the primary molded body 11, and the lower plate 12b covers the front lower surface 11b. The plate thickness T of the upper plate 12a is set to 1 mm, for example, and the plate thickness t of the lower surface 12b is set to be thinner than the upper plate 12a, for example, 0.5 mm.

一次成形体11は、図13および図14に示すように回路基板20に検出コイルを巻回したコア21、発光素子(LED)22、回路素子24等が実装されてインサートされている。電線13は、被覆材14の端末から延出する心線15〜17の端末が回路基板20に接続されている。そして回路基板20および電線13の端末が一次成形用の金型(図示せず)に収納されて一次成形樹脂25が充填され、回路基板20、コア21、発光素子22、および回路素子24等が一体的にモールドされる。   As shown in FIGS. 13 and 14, the primary molded body 11 has a core 21 around which a detection coil is wound around a circuit board 20, a light emitting element (LED) 22, a circuit element 24, and the like mounted and inserted. As for the electric wire 13, the terminal of the core wires 15-17 extended from the terminal of the coating | covering material 14 is connected to the circuit board 20. As shown in FIG. Then, the circuit board 20 and the end of the electric wire 13 are accommodated in a primary molding die (not shown) and filled with the primary molding resin 25, and the circuit board 20, the core 21, the light emitting element 22, the circuit element 24, and the like are formed. Molded integrally.

図9に示すように一次成形体11は略直方体形状をなし、回路基板20の後方にネジ取付孔(段差孔)11cが上下に貫通して設けられている。更に二次成形体との密着性の向上及び基板の変形等を防止するために上面11aから回路基板20までテーパ孔11dが複数設けられ(図13)、両側面の前後のそれぞれに溝11e、11fが設けられ、また前面中央に溝11g(図2、図4、図5)が設けられている。溝11gの下端は、前部下面11bに連設されている。上面11aと前部下面11bとを連通する溝11eの上端には凸部11hが設けられて堰が形成されている。この凸部11hは、上面11a側と前部下面11b側に充填される樹脂の流量を調節して、充填バランスを確保するためのものである。   As shown in FIG. 9, the primary molded body 11 has a substantially rectangular parallelepiped shape, and a screw attachment hole (step hole) 11 c is provided through the circuit board 20 so as to penetrate vertically. Further, in order to improve adhesion with the secondary molded body and prevent deformation of the substrate, a plurality of tapered holes 11d are provided from the upper surface 11a to the circuit board 20 (FIG. 13), and grooves 11e are formed on the front and rear sides of both sides. 11f is provided, and a groove 11g (FIGS. 2, 4, and 5) is provided in the center of the front surface. The lower end of the groove 11g is connected to the front lower surface 11b. A protrusion 11h is provided at the upper end of the groove 11e that communicates the upper surface 11a and the front lower surface 11b to form a weir. This convex part 11h is for ensuring the filling balance by adjusting the flow rate of the resin filled on the upper surface 11a side and the front lower surface 11b side.

図13に示すように一次成形体11の前部下面11bは、回路基板20に固定されているコア21の端面(検出面)21aと同一面とされ、当該前部下面11bに連設する後部下面11b’は、前部下面11bから所定の高さtに設定されている。前部下面11bの前端近傍左右両側に円柱形状の突起11iが突設されており、その高さは、前部下面11bから前記所定の高さtに設定されている。   As shown in FIG. 13, the front lower surface 11 b of the primary molded body 11 is the same surface as the end surface (detection surface) 21 a of the core 21 fixed to the circuit board 20, and the rear portion is connected to the front lower surface 11 b. The lower surface 11b ′ is set to a predetermined height t from the front lower surface 11b. Cylindrical protrusions 11i are provided on the left and right sides near the front end of the front lower surface 11b, and the height thereof is set to the predetermined height t from the front lower surface 11b.

一次成形体11を形成する樹脂25は、内蔵される回路基板20及び当該回路基板20に実装されている前記種々の回路部品や電線13の被覆14の端末等を封止して液密に保護すると共に回路基板20との線膨張率の違いによる応力を緩和するために、柔らかい樹脂(例えば、熱可塑性エラストマ系樹脂)が使用されている。また内蔵された発光素子22の光を透過させて外部から視認可能とするために半透明の樹脂が使用されている。   The resin 25 forming the primary molded body 11 seals the built-in circuit board 20, the various circuit components mounted on the circuit board 20, the terminals of the covering 14 of the electric wires 13, and the like to provide liquid-tight protection. In addition, a soft resin (for example, a thermoplastic elastomer resin) is used to relieve stress due to a difference in linear expansion coefficient with the circuit board 20. Further, a translucent resin is used to transmit light from the built-in light emitting element 22 and make it visible from the outside.

次に一次成形体11を二次成形用の金型(図示せず)に収納し、図11及び図12に示すゲートGe,Gf,Ggから溝11e,11f,11gに二次成形用の溶融した樹脂26を加圧注入して二次成形体12を成形する。この二次成形樹脂26は、一次成形体11を保護する外殻としての強度を確保し、且つ寸法精度を得るために硬い樹脂(例えばPBTやABS樹脂等)が使用される。   Next, the primary molded body 11 is housed in a mold (not shown) for secondary molding, and melted for secondary molding from the gates Ge, Gf, Gg shown in FIGS. 11 and 12 to the grooves 11e, 11f, 11g. The secondary molded body 12 is molded by pressure injection of the resin 26 thus prepared. The secondary molding resin 26 is made of a hard resin (for example, PBT or ABS resin) in order to ensure strength as an outer shell protecting the primary molded body 11 and to obtain dimensional accuracy.

ゲートGeから溝11eに注入された樹脂は、図15に示すように一次成形体11の上面11aの前部、孔11d、前部下面11bと各突起11iとの間の空間に充填されて、上板12aの前部、回路基板20の反り等の変形を防止する突起部12d、コア21の端面21aを保護する下板12b、これらの上板12aと下板12bとを連設すると共に前側部の一部を保護する補強部を兼ねた連設部12eをそれぞれ形成する。各突起11iは上面11aの前部に充填される樹脂による変形を防止して、前部下面11bと金型との間の前記空間を所定の間隔tに保持する。また先端部のゲートGgから溝11gに注入された樹脂は、前面の一部を保護する補強部12g及び下板12bの前端部を成形する。ゲートGfから溝11fに注入された樹脂は、上面11aの後部、ネジ取付孔11cの内周面に充填され、これによって上板12aの後部、ネジ取付孔11cの内周面及びネジ頭部と当接する段差面を覆うネジ取付補強部12c、回路基板20の反り等の変形を防止する突起部12d、後側部の一部を保護す補強部12f、電線13の端末を覆う保護部12j等がそれぞれ成形される。   As shown in FIG. 15, the resin injected from the gate Ge into the groove 11e fills the space between the front part of the upper surface 11a of the primary molded body 11, the hole 11d, the front lower surface 11b, and each protrusion 11i, A front portion of the upper plate 12a, a protruding portion 12d that prevents deformation of the circuit board 20 such as a warp, a lower plate 12b that protects the end surface 21a of the core 21, and the upper plate 12a and the lower plate 12b are connected to each other and the front side The connecting portions 12e that also serve as reinforcing portions for protecting a part of the portions are formed. Each protrusion 11i prevents deformation due to the resin filled in the front portion of the upper surface 11a, and holds the space between the front lower surface 11b and the mold at a predetermined interval t. Also, the resin injected from the gate Gg at the tip into the groove 11g forms the reinforcing portion 12g that protects a part of the front surface and the front end of the lower plate 12b. The resin injected from the gate Gf into the groove 11f is filled in the rear portion of the upper surface 11a and the inner peripheral surface of the screw mounting hole 11c, thereby the rear portion of the upper plate 12a, the inner peripheral surface of the screw mounting hole 11c, and the screw head. Screw mounting reinforcing portion 12c that covers the stepped surface that comes into contact, projection portion 12d that prevents deformation such as warping of the circuit board 20, reinforcing portion 12f that protects a part of the rear side portion, protective portion 12j that covers the end of the electric wire 13, etc. Are molded respectively.

下板12bは、一次成形体11の前部下面11bに密着成形され、且つ左右の突起11iにより板厚が所定の高さtに正確に成形されて下面が後部下面11b’と面一をなしている。これによりコア21の端面(検出面)21aから下板12bの下面までの距離が所定の高さtに精度よく設定され(図15)、近接センサ10の動作距離のバラツキが抑えられる。また下板12bは、前部下面11bに密着成形されることでシール性が確保され、コア21の端面21aが液密に封止される。またネジ取付孔11cの内周面及び段差面を二次成形体の樹脂で覆うことによりその強度が確保され、ネジ等で取り付ける際に近接センサ10の変形や破損等が防止されと共に、電線13の心線15〜17も保護される。   The lower plate 12b is formed in close contact with the front lower surface 11b of the primary molded body 11, and the plate thickness is accurately formed to a predetermined height t by the left and right protrusions 11i, so that the lower surface is flush with the rear lower surface 11b '. ing. As a result, the distance from the end surface (detection surface) 21a of the core 21 to the lower surface of the lower plate 12b is accurately set to a predetermined height t (FIG. 15), and variations in the operating distance of the proximity sensor 10 are suppressed. Further, the lower plate 12b is tightly formed on the front lower surface 11b to ensure sealing performance, and the end surface 21a of the core 21 is sealed in a liquid-tight manner. Moreover, the strength is ensured by covering the inner peripheral surface and the step surface of the screw mounting hole 11c with the resin of the secondary molded body, and the deformation or breakage of the proximity sensor 10 is prevented when mounting with a screw or the like, and the electric wire 13 The cores 15 to 17 are also protected.

尚、上記では一次成形体に対して二次成形体を形成する実施の形態について説明したが、これに限られるものではなく、この二次成形体に対して更に三次成形体等の多次成形体を形成することも本発明の適用範囲である。
以上説明したように本発明によれば、低次の成形体の外部を覆う熱可塑性樹脂は、前記低次の成形体の表面に設けられた突出部により流動抵抗を受けて充填率が変化し、これにより、偏肉厚部分の充填バランスが保たれ、多次成形体における前記低次の成形体の外部を覆う樹脂層の厚みが部分的に異なる場合でも精度よく成形される。
In addition, although embodiment mentioned above which forms a secondary molded object with respect to a primary molded object was described above, it is not restricted to this, Multi-molded articles, such as a tertiary molded object, are further limited with respect to this secondary molded object. Forming a body is also within the scope of the present invention.
As described above, according to the present invention, the thermoplastic resin that covers the outside of the low-order molded body is subjected to flow resistance by the protrusion provided on the surface of the low-order molded body, and the filling rate changes. Thereby, the filling balance of the uneven thickness portion is maintained, and even when the thickness of the resin layer covering the outside of the low-order molded body in the multi-order molded body is partially different, the molding is accurately performed.

そして金型のゲートから加圧注入された熱可塑性樹脂は、低次の成形体の表面に設けられた突出部により流動抵抗を受けて充填率が調節されことにより、充填バランスが確保され、多次成形体における前記低次の成形体の表面を覆う樹脂層の厚みが部分的に異なる場合でも精度よく成形することができる。また、前記金型は、低次の成形体表面に形成する突出部に応じて凹加工することで簡単に対処することができ、ゲートの位置や径の変更が不要であり金型のコストを大幅に低減することができる。更に、充填バランスの悪い形状や、低次の成形体に柔らかく強度の弱い材料を使用することも可能となり、種々の多次成形体に容易に対処することができる。   The thermoplastic resin pressure-injected from the gate of the mold is subjected to flow resistance by the protrusions provided on the surface of the lower-order molded body and the filling rate is adjusted, so that a filling balance is ensured. Even when the thickness of the resin layer covering the surface of the lower-order molded body in the subsequent molded body is partially different, the molding can be accurately performed. In addition, the mold can be easily coped with by performing concave processing according to the protrusion formed on the surface of the lower-order molded body, and there is no need to change the position and diameter of the gate, thereby reducing the cost of the mold. It can be greatly reduced. Furthermore, it is possible to use a soft and weak material for a shape having a poor filling balance or a low-order molded body, and it is possible to easily cope with various multi-order molded bodies.

本発明に係る多次成形体の第1の実施形態の斜視図である。1 is a perspective view of a first embodiment of a multi-molded product according to the present invention. 図1に示す多次成形体の低次の成形体の斜視図である。It is a perspective view of the low-order molded object of the multi-order molded object shown in FIG. 図2に示す多次成形体の矢線III-IIIに沿う断面図である。It is sectional drawing which follows the arrow line III-III of the multi-molded article shown in FIG. 図1に示す多次成形体の製造方法の説明図である。It is explanatory drawing of the manufacturing method of the multi-molded object shown in FIG. 本発明に係る多次成形体の第2の実施形態を示し、低次の成形体に設けた樹脂流路としての溝の要部を示す斜視図である。It is a perspective view which shows 2nd Embodiment of the multi-order molded object which concerns on this invention, and shows the principal part of the groove | channel as a resin flow path provided in the low-order molded object. 本発明に係る多次成形体の第3の実施形態を示し、低次の成形体に設けた樹脂流路としての溝及び金型の断面図である。FIG. 7 is a cross-sectional view of a groove and a mold as a resin flow path provided in a low-order molded body, showing a third embodiment of the multi-molded body according to the present invention. 本発明に係る多次成形体の第4の実施形態を示し、低次の成形体に設けた樹脂流路としての溝及び金型の断面図である。FIG. 9 is a cross-sectional view of a groove and a mold as a resin flow path provided in a low-order molded article, showing a fourth embodiment of a multi-molded article according to the present invention. 本発明に係る多次成形体の第5の実施形態を示し、多次成形体を適用した近接センサの斜視図である。It is a perspective view of the proximity sensor which showed 5th Embodiment of the multi-molded article concerning the present invention, and applied the multi-molded article. 図8に示す一次成形体の斜視図である。It is a perspective view of the primary molded object shown in FIG. 図8に示す二次成形体の斜視図である。It is a perspective view of the secondary molded object shown in FIG. 図9の矢線XI―XIに沿う内部を省略した断面図である。It is sectional drawing which abbreviate | omitted the inside which followed the arrow XI-XI of FIG. 図9に示す一次成形体に二次成形体を充填する金型のゲート位置の説明図である。It is explanatory drawing of the gate position of the metal mold | die which fills the primary molded object shown in FIG. 9 with a secondary molded object. 図9に示す一次成形体の矢線XIII―XIIIに沿う断面図である。FIG. 10 is a cross-sectional view taken along the arrow XIII-XIII of the primary molded body shown in FIG. 9. 図13に示す一次成形体の矢線XIV-XIVに沿う断面図である。It is sectional drawing which follows the arrow line XIV-XIV of the primary molded object shown in FIG. 図8に示す近接センサの矢線XV―XVに沿う断面図である。It is sectional drawing which follows the arrow line XV-XV of the proximity sensor shown in FIG. 従来の多次成形体の斜視図である。It is a perspective view of the conventional multi-order molded object. 図16に示す低次成形体の斜視図である。It is a perspective view of the low-order molded object shown in FIG. 図16に示す多次成形体の製造方法の説明図である。It is explanatory drawing of the manufacturing method of the multi-order molded object shown in FIG.

符号の説明Explanation of symbols

1、4 多次成形体
2 二次成形体
3 金型
3g ゲート
5〜8 一次成形体(低次成形体)
5c 溝(溶融樹脂流路)
5d,6d,7d,8d 凸部(突出部)
10 近接センサ(多次成形体)
11 一次成形体(樹脂成形体)
11a 上面
11b 前部下面
11b’ 後部下面
11e,11f,11g 溝(溶融樹脂通路)
11h 凸部(突出部)
12 二次成形体(樹脂成形体)
12a 上板
12b 下板
12e 連設部
13 電線
20 回路基板
21 コア
25 一次成形体用樹脂
26 二次成形体用樹脂
1, 4 Multi-molded body 2 Secondary molded body 3 Mold 3g Gate 5-8 Primary molded body (low-order molded body)
5c groove (molten resin flow path)
5d, 6d, 7d, 8d Convex part (protruding part)
10 Proximity sensor (multi-molded product)
11 Primary molded body (resin molded body)
11a Upper surface 11b Front lower surface 11b 'Rear lower surface 11e, 11f, 11g Groove (molten resin passage)
11h Convex part (protruding part)
12 Secondary molding (resin molding)
12a Upper plate 12b Lower plate 12e Connecting portion 13 Electric wire 20 Circuit board 21 Core 25 Primary molded body resin 26 Secondary molded body resin

Claims (3)

低次の成形体の外側に熱可塑性樹脂を一体化形成した多次成形体において、
前記熱可塑性樹脂はその表面に少なくとも2つのゲート痕を有すると共に、1つのゲート痕から他のゲート痕に至る間のそれぞれにウェルドを有し、
前記低次の成形体は、前記熱可塑性樹脂の層にて全体が覆われる突出部をその表面に備え、この突出部は少なくとも上記熱可塑性樹脂の1つのゲート痕から前記ウェルドの1つに至る間に位置することを特徴とする多次成形体。
In a multi-order molded body in which a thermoplastic resin is integrally formed on the outside of a low-order molded body,
The thermoplastic resin which has at least two gate mark on its surface, has a weld to each while extending from one gate mark on the other gate mark,
The lower order of the compact is provided with a protrusion whole in the layer of the thermoplastic resin is covered on its surface, extending the projections from at least one gate mark of the thermoplastic resin in one of the weld A multi-molded article characterized by being positioned between.
低次の成形体の外側に熱可塑性樹脂を一体化形成した多次成形体において、
前記熱可塑性樹脂はその表面に少なくとも2つのゲート痕を有すると共に、1つのゲート痕から他のゲート痕に至る間のそれぞれにウェルドを有し、
前記熱可塑性樹脂は互いに肉厚の異なる部分を有し、
前記ウェルドは前記熱可塑性樹脂の肉厚の厚い部分および肉厚の薄い部分のいずれにも位置しており、
前記低次の成形体は、前記熱可塑性樹脂の層にて全体が覆われる突出部をその表面に備え、この突出部は少なくとも前記ゲート痕の1つから前記肉厚の厚い部分のウェルドに至る間に位置することを特徴とする多次成形体。
In a multi-order molded body in which a thermoplastic resin is integrally formed on the outside of a low-order molded body,
The thermoplastic resin which has at least two gate mark on its surface, has a weld to each while extending from one gate mark on the other gate mark,
The thermoplastic resin has portions with different thicknesses from each other,
The weld is located in both the thick part and the thin part of the thermoplastic resin,
The lower-order molded body includes a protrusion on the surface thereof that is entirely covered with the thermoplastic resin layer, and the protrusion extends from at least one of the gate marks to the weld of the thick portion. A multi-molded article characterized by being positioned between.
表面に露出した電子部品を有する低次の成形体の外側に熱可塑性樹脂を一体化形成した多次成形体において、
前記熱可塑性樹脂はその表面に少なくとも2つのゲート痕を有すると共に、1つのゲート痕から他のゲート痕に至る間のそれぞれにウェルドを有し、
前記低次の成形体は、前記熱可塑性樹脂の層にて全体が覆われる突出部をその表面に備え、この突出部は少なくとも上記熱可塑性樹脂の1つのゲート痕からウェルドの1つに至る間に位置し、
前記ウェルドは前記電子部品を避けた位置にあることを特徴とする多次成形体。
In a multi-order molded body in which a thermoplastic resin is integrally formed on the outside of a low-order molded body having an electronic component exposed on the surface,
The thermoplastic resin which has at least two gate mark on its surface, has a weld to each while extending from one gate mark on the other gate mark,
During the low-order of the compact is provided with a protrusion whole in the layer of the thermoplastic resin is covered on its surface, the protrusion extending into one of the weld from one gate mark of at least the thermoplastic resin Located in
The multi-molded product according to claim 1, wherein the weld is located away from the electronic component.
JP2007173867A 2007-07-02 2007-07-02 Multi-molded body Expired - Fee Related JP4432090B2 (en)

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