JP6412336B2 - Manufacturing method of light flux controlling member - Google Patents

Description

The present invention relates to the production how the light flux controlling member.

  For some time, various lighting parts, various electric products, automobiles, and the like have been made of resin parts for the purpose of weight reduction and cost reduction. As a method for mass-producing such resin parts, injection molding is known.

  In general, in injection molding, resin is filled in a mold that has been clamped, and pressure is maintained. Next, after the mold is opened, the molded product is taken out from the mold. Further, in the step of taking out the molded product from the mold, the molded product is taken out from the mold by protruding ejector pins from the molding surface of the mold. At this time, an ejector trace of the ejector pin remains in the molded product.

  As a method for solving such a problem, a method is known in which an ejector pin is arranged at a position that does not affect the performance of a molded product (see, for example, Patent Document 1). Patent Document 1 describes a method of manufacturing a lens using injection molding in which an ejected pin of an ejector pin does not remain on an optical surface (lens). 1A to 1C are diagrams showing a state of a lens manufacturing method using injection molding described in Patent Document 1. FIG. As shown in FIGS. 1A to 1C, a molding apparatus 10 used for injection molding described in Patent Document 1 has a mold 50 including a first mold 20, a second mold 30, and a core 40. The first mold 20 has a first optical surface transfer surface 22 for forming a part of the lens 60 and a first flange portion transfer surface 24 for forming a part of the flange portion 62. The second mold 30 is formed in the central portion, is disposed opposite the opening 32 where the core 40 is disposed, and the first flange portion transfer surface 24, and is a second for molding the other portion of the flange portion 62. And a flange portion transfer surface 34. The core 40 is disposed in the opening 32 so as to face the first optical surface transfer surface 22 and has a second optical surface transfer surface 42 for molding the other part of the lens 60. In addition, an ejector pin 70 is disposed in the small opening 36 opened in the second flange portion transfer surface 34 so as to protrude from the second flange portion transfer surface 34.

  In the lens manufacturing method using injection molding using the molding apparatus 10, the first mold 20 and the second mold 30 are clamped. Then, the molten resin is filled in the mold 50 to hold the pressure (see FIG. 1A). Next, after the first mold 20 and the second mold 30 are opened, the core 40 is moved so as to separate the second optical surface transfer surface 42 from the lens 60 (see FIG. 1B). Finally, the lens 60 is taken out from the mold 50 by causing the ejector pin 70 to protrude from the second flange portion transfer surface 34 (see FIG. 1C).

  In the injection molding described in Patent Document 1, the ejector pin 70 does not remain on the optical surface because the lens 60 is taken out from the mold 50 by the ejector pin 70 pushing out the flange portion 62. Further, as a mold release method using other than the ejector pin 70, there is a method of pushing the entire second optical surface transfer surface 42 by sliding the core 40 within the opening 32. In this case as well, no trace of extrusion remains on the optical surface.

JP 2013-126774 A

  However, as described in Patent Document 1, in injection molding using a mold in which a small opening 36 for inserting and removing the ejector pin 70 (sliding piece) is opened on the inner surface of the cavity, a low-viscosity resin material ( When a thermosetting resin material is used, the resin material enters the sliding portion between the small opening 36 and the ejector pin 70, and the ejector pin 70 (sliding piece) or the like causes a malfunction. There was a problem.

  Therefore, an object of the present invention is to provide a method for producing a thermosetting resin molded product in which an injection molding apparatus does not cause malfunction even when a low-viscosity thermosetting resin material is used. And

  Another object of the present invention is to provide a molded article of a thermosetting resin obtained by the production method.

  A method for producing a molded article according to the present invention is a method for producing a thermosetting resin molded article by injection molding, and is a through-hole for sliding a sliding piece opened on the inner surface of a cavity of a mold. A sealing member disposed in the cavity so as not to block the filling hole for filling the cavity with the thermosetting resin, and the thermosetting resin from the filling hole to the cavity. Filling and curing the material to obtain a thermosetting resin molded product, and projecting the sliding piece from the through-hole so as to push out the sealing member, from the mold to the sealing member And a step of taking out the molded product.

  The molded product according to the present invention is a molded product obtained by the method for manufacturing a molded product of the present invention, and the seal member is bonded to the molded product via a primer layer.

  In the method of manufacturing a molded product according to the present invention, since the sealing member covers the through-hole through which the sliding piece is taken in and out, the thermosetting resin material does not enter the sliding portion of the sliding piece, and the injection molding apparatus Can prevent malfunction. In addition, the molded product obtained by the manufacturing method does not impair the quality because the sliding piece does not contact the molded product.

1A to 1C are views showing a state of a lens manufacturing method by injection molding described in Patent Document 1. FIG. 2A to 2C are diagrams showing a configuration of a molded product according to the embodiment. 3A to 3C are diagrams illustrating the configuration of the seal member according to the embodiment. 4A to 4D are diagrams illustrating a molded product and a configuration of the molded product according to the embodiment. FIG. 5 is a schematic view showing an injection molding apparatus used in the method for manufacturing a molded product according to the embodiment. FIG. 6 is a flowchart showing an operation procedure of the injection molding apparatus. 7A to 7C are schematic diagrams illustrating an operation procedure of the injection molding apparatus. 8A to 8C are schematic diagrams illustrating the operation procedure of the injection molding apparatus.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the present embodiment, a description will be given by taking, as an example, a light flux controlling member that controls the light distribution of light emitted from a light source as a molded product.

(Molding)
First, a molded product manufactured by the method for manufacturing a molded product according to the present invention will be described. FIG. 2 is a diagram showing a configuration of a molded product. 2A is a plan view of the molded article 100, FIG. 2B is a side view, and FIG. 2C is a cross-sectional view taken along line AA shown in FIG. 2A.

  As shown in FIGS. 2A to 2C, the molded product 100 is a light flux control member made of a thermosetting resin that controls light distribution of light emitted from a light source. The molded product 100 has a back surface 120, an entrance surface 140, and an exit surface 160. The molded product 100 is a substantially rotating body around the central axis. A gate mark 180 remains on a part of the emission surface 160.

  The back surface 120 is disposed on the back side. The surface shape of the back surface 120 is not particularly limited. Although not particularly illustrated, in the present embodiment, the surface shape of the back surface 120 has a plurality of ridges formed in a lattice shape. In the central portion of the back surface 120, a recess whose inner surface becomes the incident surface 140 is opened. An engagement groove 124 that engages with an engagement step 242 of the seal member 200 described later is formed on the outer peripheral edge of the back surface 120.

  The incident surface 140 allows light emitted from the light source to enter. The incident surface 140 is an inner surface of a recess opened in the back surface 120. The opening edge of the recess protrudes outward from the back surface 120. The incident surface 140 is a rotationally symmetric surface, and the central axis of the incident surface 140 coincides with the central axis of the molded product 100.

  The exit surface 160 emits the light incident on the entrance surface 140 to the outside of the molded product 100. The emission surface 160 includes a first emission surface 161 located in a predetermined range centered on the central axis of the emission surface 160, a second emission surface 162 formed continuously around the first emission surface 161, and a second It has the 3rd output surface 163 which connects the output surface 162 and the back surface 120. FIG. The shape of the first emission surface 161 is a smooth curved surface that protrudes downward (to the light source side). The shape of the second emission surface 162 is an annular convex shape. The third emission surface 163 is a curved surface located around the second emission surface 162.

  The kind of thermosetting resin which comprises the molded article 100 is not specifically limited. In this Embodiment, the thermosetting resin which comprises the molded article 100 will not be specifically limited if it can permeate | transmit a predetermined wavelength from a viewpoint of controlling the light distribution of the light radiate | emitted from the light source. Examples of thermosetting resins that can be used in this embodiment include silicone resins, acrylic resins, organic-inorganic hybrid resins containing silsesquioxane, allyl ester resins, urethane resins, and the like. In addition, in the case where the surface treatment described later is necessary, the thermosetting resin is an organic-inorganic hybrid resin containing a silicone resin or silsesquioxane in order to exert the effect of the surface treatment in the mold 320. It is preferable. In addition, the kind of thermosetting resin can be suitably selected with the molded article 100 to manufacture.

(Seal member)
Next, the seal member 200 arranged on the back surface 120 side of the molded product 100 in the injection molding will be described. FIG. 3 is a diagram illustrating a configuration of the seal member 200 according to the embodiment. 3A is a plan view of the seal member 200, FIG. 3B is a bottom view, and FIG. 3C is a side view.

  The seal member 200 closes the fourth through-hole 369 in which the ejector pin 380 of the mold 320 used in the method of manufacturing the molded article 100 is slid, and fills the cavity with a thermosetting resin material. This is a substantially disk-shaped member that does not block the filling hole 366 (see FIG. 5). The seal member 200 has a seal surface 220, a pedestal surface 240, and leg portions 260. A first through-hole 202 is formed in the central portion of the seal member 200 so that the opening on the pedestal surface 240 side is continuous with the opening edge of the incident surface 140. The first through hole 202 is formed in a tapered shape such that its diameter increases from the opening of the seal surface 220 toward the opening of the pedestal surface 240.

  The seal surface 220 is a surface that closes the fourth through-hole 369 on which the ejector pin 380, which is a sliding piece of the mold 320, slides (see FIG. 5). The seal surface 220 is provided with three legs 260.

  The pedestal surface 240 is a molding surface for molding the back surface 120 of the molded product 100. An engaging step portion 242 that engages with the engaging groove 124 of the molded product 100 is formed on the outer peripheral edge portion of the pedestal surface 240. Further, a notch groove 244 is formed in a part of the engaging step portion 242 at a position corresponding to the gate mark 180 of the molded product 100. The notch groove 244 serves as an inflow port for the thermosetting resin material in the injection molding. The surface shape of the pedestal surface 240 is not particularly limited. In the present embodiment, a plurality of grooves 246 are formed in a lattice shape on the surface of the pedestal surface 240.

  The material of the seal member 200 is not particularly limited as long as the material has high heat resistance to such an extent that it does not deform at the molding temperature in injection molding. Specifically, the material of the seal member 200 may be any material whose deflection temperature under load is higher than a molding temperature described later. Thereby, the sealing member 200 does not deform | transform at the time of filling of the thermosetting resin in injection molding. Examples of the material of the seal member 200 include resin and metal. Examples of resins include polyphenylene sulfide (PPS), polyetherimide (PEI), polyethersulfone (PES), polybutylene terephthalate (PBT), polyamide 9T (PA9T), polyamide 6T (PA6T), polysulfone (PSU) , Polyarate (PAR), amorphous thermoplastic polyimide (TPI), polybenzimidazole (PBI), polyamideimide (PAI), GF reinforced polycyclohexyleneethylene terephthalate (GF-PCT), GF reinforced syndiotactic polystyrene resin ( Thermoplastic resins such as GF-SPS and polyetheretherketone (PEEK) are included. Table 1 shows various temperatures of the thermoplastic resin that can be used in the present embodiment.

  In addition, the sealing member 200 may be joined to the molded article 100 through the below-mentioned primer layer (refer FIG. 4). Although details will be described later, in this case, the primer layer can be formed by surface-treating the pedestal surface 240 of the seal member 200 with the molded product 100. Thereafter, a bonded product can be obtained by filling and curing the thermosetting resin material.

(Injection molding equipment)
Next, the mold 320 of the injection molding apparatus 300 for manufacturing the molded product 100 will be described. FIG. 5 is a cross-sectional view schematically showing the mold 320. In FIG. 5, hatching is omitted.

  As shown in FIG. 5, the mold 320 includes a first mold 340, a second mold 360 and an ejector pin 380. Although not particularly illustrated, the mold 320 is configured to be connectable to an injection unit having a hopper and a cylinder, and the inside of the clamped mold 320 (the first mold 340 and the second mold 360) ( The cavity) can be filled with a thermosetting resin material.

  The first mold 340 is a mold piece for molding the emission surface 160 side of the molded product 100. The first mold 340 includes a guide part 342 and a first mold body 344.

  A first mold body 344 for injection molding the molded product 100 is incorporated in the guide part 342.

  The first mold body 344 has a first plane 346 and an exit surface transfer surface 348. The first plane 346 is a surface that is disposed to face the second plane 363 of the second mold 360. In the central portion of the first plane 346, a concave portion whose inner surface becomes the exit surface transfer surface 348 is opened.

  As described above, the exit surface transfer surface 348 is the inner surface of the recess opened in the central portion of the first plane 346. The exit surface transfer surface 348 is formed in a shape corresponding to the exit surface 160 (see FIG. 2) of the molded product 100 described above.

  The second mold 360 is a mold piece arranged on the incident surface 140 side of the molded product 100. The second mold 360 has a second mold main body 361 and an incident surface molding part 362.

  The second mold main body 361 includes a second flat surface 363, a seal member arrangement portion 364, a third through hole 368 and a fourth through hole 369.

  The second plane 363 is a plane disposed so as to face the first plane 346. That is, the first plane 346 of the first mold 340 and the second plane 363 of the second mold 360 are parting surfaces (P) of the mold 320. The second flat surface 363 is formed with a filling groove 365 that communicates with the outside of the mold 320 and the cavity and serves as a filling hole 366 for filling the mold 320 with the thermosetting resin. The first mold 340 and the second mold 360 are clamped, and a filling hole 366 is formed by covering the opening of the filling groove 365 with the lower surface of the guide portion 342 and the first plane 346.

  The seal member disposition portion 364 is a recess that opens at the center portion of the second plane 363. The seal member arrangement part 364 is a part for arranging the seal member 200. The seal member arrangement part 364 has a shape complementary to the seal member 200. That is, the planar view shape of the seal member disposition portion 364 is the same as the planar view shape of the seal member 200 (see FIG. 3). Furthermore, one third through hole 368 for incorporating the incident surface transfer surface 367 of the incident surface molding unit 362 and a plurality of fourth through holes for sliding the ejector pins 380 are included in the seal member arrangement portion 364. Each of the holes 369 is open. The number of the fourth through holes 369 is not particularly limited. There may be one or more. In the present embodiment, two fourth through holes 369 are formed. By installing the seal member 200 in the seal member arrangement portion 364, the two fourth through holes 369 are closed by the seal member 200.

  The entrance surface molding portion 362 is disposed so as to be insertable into the third through hole 368 of the seal member placement portion 364. The incident surface molding unit 362 has an incident surface transfer surface 367.

  The incident surface transfer surface 367 is a portion for molding the incident surface 140 of the molded product 100. The incident surface transfer surface 367 has a shape complementary to the incident surface 140 of the molded product 100.

  The ejector pin 380 is used to take out the molded product 100 from the mold 320 by protruding toward the cavity and pushing the seal member 200. The ejector pin 380 is slidably disposed with respect to the fourth through hole 369 of the seal member disposing portion 364. The ejector pin 380 slides so as to protrude from the bottom surface of the seal member disposition portion 364. The ejector pin 380 is attached so as to be movable between a molding position where injection molding is performed and a take-out position where the tip surface protrudes from the fourth through hole 369.

(Method for manufacturing molded products)
Next, an operation procedure of the mold 320 of the injection molding apparatus 300 (a method for manufacturing a molded product according to the present embodiment) will be described. FIG. 6 is a flowchart of the method for manufacturing the molded article 100 according to the present embodiment. 7 and 8 are schematic views showing the operation procedure of the mold 320. FIG.

  First, the sealing member 200 installed in the 2nd metal mold | die 360 is prepared (S100). The manufacturing method of the sealing member 200 is not particularly limited. When the material of the seal member 200 is the resin described above, examples of the method for manufacturing the seal member 200 include injection molding.

  Next, the mold 320 is opened and the seal member 200 is disposed (S110, FIG. 7A).

  Next, the first through hole 202 of the seal member 200 is fitted into the entrance surface transfer surface 367 and the seal member 200 is fitted into the seal member placement portion 364. Thereby, the sealing member 200 is installed in the 2nd metal mold | die 360 (FIG. 7B). At this time, the fourth through hole 369 into which the ejector pin 380 is inserted and removed by the seal member 200 is closed, but the filling hole 366 for filling the material of the thermosetting resin is not closed.

  Then, the first mold 340 and the second mold 340 are arranged so that the seal member 200 installed on the second mold 360 and the emission surface transfer surface 348 face each other, and the second plane 363 and the first plane 346 face each other. The mold 360 is clamped (S120, FIG. 7C).

  Next, the thermosetting resin material is filled into the mold 320 (cavity) through the filling hole 366 (S130, FIG. 8A).

  The temperature (molding temperature) of the first mold 340 and the second mold 360 may be appropriately set in consideration of the load deflection temperature of the seal member 200. The temperature of the 1st metal mold | die 340 and the 2nd metal mold | die 360 is about 130-200 degreeC. The filling time of the thermosetting resin material is about 0.3 to 15 seconds.

  In the step of holding pressure, the mold 320 is naturally cooled while holding pressure in a state in which the thermosetting resin material is filled in the mold 320 (S140). As a result, the thermosetting resin material filled in the cavity having the exit surface transfer surface 348 is cured to form the thermosetting resin molded product 100.

  Next, the mold 320 is opened (S150, FIG. 8B).

  Finally, the ejector pin 380 is moved from the molding position to the removal position, the seal member 200 is pushed out by the ejector pin 380, and the molded product 100 is removed from the second mold 360 (S160, FIG. 8C). The sealing member 200 and the molded product 100 taken out from the mold 320 can be used separately.

  Through the above steps, the molded product 100 can be obtained by injection molding. At this time, the molding cycle of injection molding is about 30 seconds to 5 minutes.

  When obtaining a bonded product in which the sealing member 200 is bonded to the molded product 100 via a primer layer, a silicone resin is used as the thermosetting resin, and the pedestal surface of the sealing member 200 in contact with the thermosetting resin Surface treatment is performed on 240. Specifically, the primer layer is formed after cleaning and activating the pedestal surface 240. The method for cleaning and activating the pedestal surface 240 is not particularly limited. The method for activating the pedestal surface 240 includes plasma treatment using oxygen, ozone, nitrogen, or the like. Note that plasma treatment using oxygen is preferable from the viewpoint of operability. Moreover, the primer coating material which forms a primer layer will not be specifically limited if the sealing member 200 and the molded article 100 (product made from a silicone resin) can be adhere | attached. A silane coupling agent can be used as the primer coating. This is because the organic functional group of the silane coupling agent reacts with the silicone resin, so that the silane coupling agent functions as an adhesive. Then, a primer layer is formed according to conditions suitable for the primer paint used. As a general primer treatment condition, the applied primer coating is dried at room temperature (20 to 25 ° C.) and normal humidity (45 to 55% Rh) to form a primer layer.

(effect)
As described above, the manufacturing method for manufacturing the molded product 100 according to the present embodiment and the molded product 100 obtained by the manufacturing method cover the ejector pin 380 that is a sliding piece at the time of injection molding with the seal member 200. Therefore, the thermosetting resin can be prevented from entering the sliding portion of the ejector pin 380. Thereby, it is possible to prevent the sliding portion of the mold 320 from malfunctioning. Moreover, since the ejector pin 380 does not contact the molded article 100 obtained by the manufacturing method, quality is not impaired.

  A method for manufacturing a molded product according to the present invention and a molded product obtained by the manufacturing method include, for example, a light flux controlling member that controls the light distribution of light emitted from a light source in a backlight or general illumination of a liquid crystal display Etc.

DESCRIPTION OF SYMBOLS 10 Molding apparatus 20 1st metal mold | die 22 1st optical surface transfer surface 24 1st flange part transfer surface 30 2nd metal mold 32 Opening 34 2nd flange part transfer surface 36 Small opening 40 Core 42 2nd optical surface transfer surface 50 Gold | metal | money Mold 60 Lens 62 Flange portion 70 Ejector pin 100 Molded product 120 Back surface 124 Engagement groove 140 Incident surface 160 Emission surface 161 First emission surface 162 Second emission surface 163 Third emission surface 180 Gate trace 200 Seal member 202 First through hole 220 sealing surface 240 pedestal surface 242 engagement step 244 notch groove 246 groove 260 leg 300 injection molding device 320 mold 340 first mold 342 guide section 343 second through hole 344 first mold main body 346 first plane 348 Emission surface transfer surface 360 Second mold 361 Second mold body 362 Incident surface molding portion 363 Second flat Surface 364 Seal member arrangement portion 365 Filling groove 366 Filling hole 367 Incident surface transfer surface 368 Third through hole 369 Fourth through hole 380 Ejector pin

Claims (3)

A light flux controlling member body made of silicone resin, including a back surface disposed on the back side, an incident surface that is an inner surface of a recess opening in the back surface, and an exit surface disposed on the opposite side of the incident surface;
Having a plurality of legs, a manufacturing method of a light flux controlling member for a pedestal made of joined thermoplastic resin, manufacture Ri by the light flux control member to an injection molding with which the rear surface,
The cavity is formed so as to close a through hole opened on the inner surface of the cavity of the mold for sliding the sliding piece and not to fill the filling hole for filling the cavity with the silicone resin. Arranging the pedestal part in
Filling the cavity from the filling hole with the silicone resin so as to come into contact with the pedestal portion and curing it to obtain the light flux controlling member main body joined to the pedestal portion ;
Projecting the sliding piece from the through-hole so as to push out the pedestal, and taking out the light flux controlling member from the mold; and
Having
Manufacturing method of light flux controlling member . Further comprising the step of forming a primer layer and dried by pre-Symbol applying the silane coupling agent to the surface where the silicone resin is in contact of the base portion prior to filling the silicone resin, according to 請 Motomeko 1 Manufacturing method of light flux controlling member . A plurality of grooves are formed in a lattice shape on the pedestal surface of the pedestal portion facing the light flux controlling member,
A notch groove for filling the silicone resin is formed in a part of the engagement end portion disposed on the outer periphery of the pedestal portion.
The manufacturing method of the light beam control member of Claim 1 or Claim 2.

Images