JP7303758B2 - Manufacturing method of injection molding - Google Patents

Description

The present invention relates to a method for manufacturing an injection molded article.

BACKGROUND ART A vehicle lamp comprising a lens and a housing is known as an example of an injection-molded article attached to a door mirror or the like of an automobile. In this vehicle lamp, a lens and a housing are injection-molded with different resin materials, and a transparent elongated light guide member, a substrate, and the like are incorporated therein.

As a method of manufacturing the vehicle lamp, Patent Document 1 discloses assembling by abutting the outer peripheral edge of the housing against the outer peripheral edge of the lens.

JP 2010-108825 A

In the vehicle lamp manufacturing method described in Patent Document 1, a device different from an injection molding device for molding the housing and the lens is used to assemble the housing and the lens.

Therefore, when assembling the housing and the lens, it is necessary to prepare the respective members by injection-molding the housing and the lens by an injection molding machine in advance. That is, in the case of such an assembly method, stock of housings and lenses is required.

As a result, it is necessary to store molded products for housings and lenses, and it is also necessary to manage the inventory of housings and lenses. there were.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method for manufacturing an injection-molded article in which the efficiency of assembly of the injection-molded article is improved and the working space is effectively used.

One aspect of the present invention is a rotary table; A method of manufacturing an injection-molded article using an injection molding apparatus having fourth, fifth and sixth molds that are opened and clamped with respect to a third mold. Then, (a) the first and fourth molds are opposed to each other and clamped, and a first resin material is injected into the clamped first and fourth molds to form a first resin member. (b) clamping the second and fifth molds facing each other, and injecting a second resin material into the clamped second and fifth molds to form a first molded member; and a step of (c) holding the first resin member by the first mold and holding the first molded member by the second mold, opening each mold; (d) each of The mold is clamped, the second resin material is injected into the first and sixth molds in the clamped state to mold the second resin member, and the second resin member is molded into the first resin member. and forming a second molded member by bonding to the resin member. (e) holding the first molding member by the second mold and holding the second molding member by the sixth mold, opening each mold; (f) rotating the rotary table in the predetermined direction to face the first and fifth molds, the second and sixth molds, and the third and fourth molds; Each mold is clamped, and a third resin material is injected into the second and sixth molds in this clamped state, and the first molded member and the second molded member are formed by the third resin material. and joining.

Another aspect of the present invention is that in the step (a), a material having translucency is injected as the first resin material, and in the step (d), the second resin material is opaque. Inject material.

In another aspect of the present invention, in the step (f), a third resin member is molded from the third resin material, and the third resin member is assembled with the first molded member to form the third resin member. joins the first molding member and the second molding member.

In another aspect of the present invention, after the step (b) and before the step (f), a light-emitting element and a light guide lens for guiding the light emitted from the light-emitting element to the first molding member. and the step of mounting.

According to the present invention, it is possible to improve the efficiency of assembling an injection-molded body and effectively utilize the working space.

BRIEF DESCRIPTION OF THE DRAWINGS It is a figure which shows the structure of the mirror apparatus to which the lamp|ramp of this invention is attached, (a) is a rear view, (b) is a front view. 1 is a perspective view showing the structure of a lamp according to an embodiment of the invention; FIG. FIG. 3 is an enlarged cross-sectional view showing a cut surface along line AA shown in FIG. 2; FIG. 3 is a front view showing the internal structure of the lamp shown in FIG. 2; BRIEF DESCRIPTION OF THE DRAWINGS It is a schematic diagram which shows the structure of the injection molding apparatus of embodiment of this invention. (a), (b), and (c) are conceptual diagrams showing procedures for assembling a lamp using molds according to the embodiment of the present invention. FIG. 3 is a perspective view showing the structure of a transparent portion of a lens in the lamp shown in FIG. 2; FIG. 3 is a perspective view showing the structure of a housing in the lamp shown in FIG. 2; 3 is a perspective view showing the structure of a lens in the lamp shown in FIG. 2; FIG. It is a perspective view which shows the state which assembled|assembled the housing and lens of embodiment of this invention.

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

The injection-molded article of the present embodiment is assembled to a mirror device attached to an automobile body, for example, a door or a fender. In this embodiment, a lamp 1 as shown in FIG. 2 will be described as an example of an injection molded body. Further, as an example of constituent members of the lamp 1, a housing (first molded member) 2 and a lens (second molded member) 3 are taken up. In other words, the injection-molded article of this embodiment is the lamp 1 having the housing 2 and the lens 3, which are respectively molded by injection molding. The lamp 1 has a hollow structure, and an encapsulating member is mounted in this hollow portion (accommodating portion 2a shown in FIG. 3, which will be described later). The housing 2 and the lens 3 are made of different resin materials, for example.

Here, the mirror device 20 shown in FIGS. 1A and 1B includes a stay bracket 27 fixed to the vehicle body and a body 25 attached to the stay bracket 27 via a folding mechanism (not shown). and a mirror 26 housed in a body 25. - 特許庁Further, the mirror device 20 includes a lamp 1 provided at a portion of the body 25 opposite to the portion where the mirror 26 is arranged, stay covers 23 and 24 covering the stay bracket 27, and a main cover 21 covering the periphery of the lamp 1. and a low cover 22. Further, the main cover 21 covers part of the periphery of the lamp 1 and the low cover 22 covers the other part of the periphery of the lamp 1 . Note that the main cover 21 also covers the mirror 26 .

The lamp 1 attached to the mirror device 20 blinks when the driver operates a switch provided in the interior of the vehicle. Thereby, the lamp 1 serves as a direction indicator.

FIG. 2 is a perspective view of the lamp 1. FIG. 2 shows the appearance of the lamp as a whole, including the exposed portion and non-exposed portion of the lamp 1, when the mirror device 20 of FIG. 1 is viewed from the front side of the automobile. ing. The width direction of the lamp 1 shown in FIG. 2 is the same direction as the extending direction P of the housing 2 shown in FIG.

2 to 4, the configuration of the lamp 1 of the present embodiment will be described. and a lens (second molded member) 3 that is bonded to the housing 2; and a resin bonding material 9 that contacts the housing 2 and the lens 3 to bond the housing 2 and the lens 3 together. there is

As shown in FIG. 3, in the lamp (injection-molded body) 1 of the present embodiment, the lens 3, which is a component thereof, includes a translucent portion (first resin member) 3d and an opaque portion (second resin member) 3d. ) 3 f , and an outer peripheral portion 3 g of the opaque portion 3 f and an outer peripheral portion 2 g of the housing 2 are joined at a joint portion 4 .

The housing 2 is made of a resin material that does not allow light to pass through, and the housing portion 2a thereof is covered with the ceiling wall 3a of the lens 3. As shown in FIG.

The light-transmitting portion 3d of the lens 3 is made of a transparent resin material that transmits light, while the non-light-transmitting portion 3f of the lens 3 that is joined to the housing 2 is made of an opaque resin material that does not transmit light.

Furthermore, wind noise countermeasure members 28 and 29 are attached to the surface of the lens 3 except for the transparent portion 3d. The wind noise countermeasure members 28 and 29 are members that reduce wind noise between the lens 3 and the main cover 21 and the low cover 22 while the automobile is running by contacting the inner surfaces of the main cover 21 and the low cover 22. .

Further, in the lens 3, a portion of the outer peripheral portion 3c of the translucent portion 3d and a portion of the outer peripheral portion 3g of the opaque portion 3f are butted and joined. More specifically, uneven fitting portions 3j and 3k are formed on parts of the outer peripheral portions 3c and 3g of the translucent portion 3d and the non-translucent portion 3f, respectively. , the projections and depressions of the fitting portion 3j and the fitting portion 3k are in contact with each other.

Further, the wall portion 3b of the opaque portion 3f of the lens 3 is in contact with the outer peripheral portion 2g connected to the bottom portion 2e of the housing 2 and the wall portion 2d. A resin bonding material 9 is provided so as to be in close contact with the end face 3e of the outer peripheral portion 3g of the wall portion 3b of the lens 3 and the end face 2h of the outer peripheral portion 2g of the housing 2. As shown in FIG. In other words, the non-light-transmitting portion 3f of the lens 3 and the housing 2 are bonded by the resin bonding material 9. As shown in FIG.

Also, in the lens 3 , the translucent portion 3 d is arranged to face the inner lens member 5 . In other words, the inner lens member 5 is arranged between the transparent portion 3 d of the lens 3 and the housing 2 .

As shown in FIG. 4, the accommodating portion 2a of the housing 2 accommodates an LED (Light Emitting Diode) 8, which is a light emitting element, and an inner lens member 5 as sealing members. The inner lens member 5 is a light guiding lens that guides the light emitted from the LED 8 toward the translucent portion 3d of the lens 3 shown in FIG. is.

Furthermore, the board|substrate 6 which has the wiring 6a electrically connected with LED8 is accommodated in the accommodating part 2a. The substrate 6 is attached to the fixing plate 15 and positioned by two positioning pins 16 . A terminal 7 that is a connection terminal for transmitting and receiving signals to and from the outside of the lamp 1 is attached to the substrate 6 . Further, the LED 8 is mounted on the sub-board 6b arranged at the end of the housing portion 2a and arranged inside the inner lens member 5. As shown in FIG.

In the lamp 1, when a voltage is applied to the LED 8 through the wiring 6a, the LED 8 is lit. Light emitted from the LED 8 enters the inner lens member 5 and is reflected within the inner lens member 5 . The reflected light passes through the transparent portion 3 d of the lens 3 and reaches the outside of the lamp 1 .

That is, in the lamp 1, the light emitted from the LED 8 is guided to the tip side of the lamp 1 by the inner lens member 5, passes through the translucent portion 3d of the lens 3, and reaches the front side of the lamp 1 (the front side of the automobile). released. In addition to the LED 8, another LED (not shown) is provided on the sub-board 6b. The light emitted from this LED passes through the lens 3 and is emitted to the rear side of the lamp 1 (the rear side of the automobile) through a viewing portion (viewing window) 25a shown in FIG. 1(b). However, since the housing 2 is made of a resin material that does not transmit light, light is not directly emitted from the portion other than the light transmitting portion 3d of the lens 3 due to the structure of the housing 2 itself.

In the lamp 1, the translucent portion 3d of the lens 3 and the inner lens member 5 are arranged close to each other so that they face each other. In the direction perpendicular to the extending direction P of the lens 3 shown in FIG. 2, as shown in FIG. A portion 3f is provided. As a result, light reflected within the inner lens member 5 is not transmitted to the outside at the opaque portion 3f. Therefore, the light reflected within the inner lens member 5 is emitted to the outside only through the translucent portion 3d of the lens 3. As shown in FIG.

Next, a method for manufacturing the lamp 1 will be described.

First, the injection molding apparatus 10 of this embodiment will be described with reference to FIG. The injection molding apparatus 10 has a first rotational position (initial position) where injection molding is performed, and a predetermined rotational position with respect to the first rotational position on the circumference of the rotation center C (see FIG. 6) where injection molding is performed. Rotation to rotate to a second rotational position located at an angle, and a third rotational position where injection molding is performed and located at a predetermined angle with respect to the second rotational position on the circumference of the center of rotation C A table 11 is provided. In this embodiment, a case where the predetermined angle is 120° will be described. That is, the first rotational position, the second rotational position, and the third rotational position are positioned at an angle of 120° to each other on the circumference of the rotation center C of the turntable 11 . The rotary table 11 is rotatable in a predetermined direction, for example, 360 degrees counterclockwise.

The injection molding apparatus 10 also includes a first mold 31, a second mold 32, and a third mold 33 arranged on the turntable 11 at predetermined intervals along the direction of rotation of the turntable 11. . In this embodiment, the molds (the first mold 31, the second mold 32 and the third mold 33) are arranged at an angle of 120° on the circumference of the rotation center C on the rotary table 11. explain if That is, the first mold 31 , the second mold 32 and the third mold 33 are lower molds arranged on the turntable 11 at 120° intervals along the rotation direction of the turntable 11 . As shown in FIG. 6, if the injection positions (molding positions) divided by 120° on the rotary table 11 are defined as X molding position, Y molding position, and Z molding position, respectively (in FIG. 6, X , Y and Z), for example, at the initial position of the rotary table 11, the first mold 31 is arranged at the X molding position, the second mold 32 is arranged at the Y molding position, and the second mold 32 is arranged at the Z molding position. Three molds 33 are arranged.

Then, as shown in FIG. 5, the injection molding apparatus 10 includes a fourth mold 34 and a fifth mold 34 for opening and closing the first mold 31, the second mold 32 and the third mold 33. A mold 35 and a sixth mold 36 are provided. The fourth mold 34, the fifth mold 35 and the sixth mold 36 are upper molds. Furthermore, the injection molding apparatus 10 includes a first injection device 12, a second injection device 13 and a third injection device 14 for injecting resin into the clamped mold. The first injection device 12 has an injection cylinder 12a and is arranged above the fourth mold 34, and the second injection device 13 has an injection cylinder 13a and is arranged above the fifth mold 35. The third injection device 14 has an injection cylinder 14 a and is arranged above the sixth mold 36 .

That is, in the injection molding apparatus 10, the first injection device 12 is attached to the fourth mold 34, the second injection device 13 is attached to the fifth mold 35, and the third injection device is attached to the sixth mold 36. 14 is attached. The first injection device 12 includes an injection cylinder 12a having an injection port 12b. The second injection device 13 has an injection cylinder 13a with an injection port 13b, and the third injection device 14 has an injection cylinder 14a with an injection port 14b.

In the injection molding apparatus 10, a control unit (not shown) controls the rotation of the turntable 11, the opening and closing of the mold, and the injection from each injection device. Specifically, for any one of the first mold 31, the second mold 32 and the third mold 33 which are the lower molds, the fourth mold 34, the fifth mold 35 and the third mold which are the upper molds. 6. Injection operations such as the operation of approaching and separating the 6 molds 36, each injection device to be used, the resin to be used and the timing of injection are controlled by the control unit, and the first injection device 12 and the second injection device 13 and the third injection device 14, the necessary resin is injected from the injection ports of the respective injection cylinders at the necessary timing.

Further, as the position control of the turntable 11, the control section performs control to execute first position control, second position control and third position control on the turntable 11, for example. When the first position control is executed, the first mold 31 and the fourth mold 34 face each other, the second mold 32 and the fifth mold 35 face each other, and the third mold The turntable 11 rotates to the first rotation position where the mold 33 and the sixth mold 36 face each other. That is, the rotary table 11 is at the initial position shown in FIG. 6(a). Further, when the second position control is executed, the first mold 31 and the sixth mold 36 face each other, the second mold 32 and the fourth mold 34 face each other, and the third mold 32 and the fourth mold 34 face each other. The rotary table 11 rotates to the second rotation position where the mold 33 and the fifth mold 35 face each other. That is, the rotary table 11 is at the position shown in FIG. 6(b). Furthermore, when the third position control is executed, the first mold 31 and the fifth mold 35 face each other, the second mold 32 and the sixth mold 36 face each other, and the third mold 32 and the sixth mold 36 face each other. The rotary table 11 rotates to the third rotation position where the mold 33 and the fourth mold 34 face each other. That is, the rotary table 11 is at the position shown in FIG. 6(c).

Next, the assembly procedure shown in FIG. 6 will be described.

As shown in FIG. 6A, at the initial position of the rotary table 11, the first mold 31 and the fourth mold 34, the second mold 32 and the fifth mold 35, the third mold 33 and the sixth mold The molds 36 are opposed to each other and clamped, the first resin material is injected into the clamped first mold 31 and the fourth mold 34, and the translucent part (first mold) as shown in FIG. Resin member) 3d is molded (primary molding). The first resin material is a translucent resin material. Therefore, the translucent portion 3d has translucency.

A second resin material is injected into the clamped second mold 32 and fifth mold 35 to mold a housing (first molding member) 2 as shown in FIG. 8 (primary molding). . The second resin material is a non-light-transmitting resin material. Therefore, the housing 2 is an opaque member.

After molding the light-transmitting portion 3d and the housing 2, the molds are opened while the light-transmitting portion 3d is held by the first mold 31 and the housing 2 is held by the second mold 32. FIG. Then, in this mold open state, the rotary table 11 is rotated in a predetermined direction, for example, 120° counterclockwise to form a first mold 31, a sixth mold 36, and a second mold 36 as shown in FIG. 6(b). The mold 32 and the fourth mold 34, and the third mold 33 and the fifth mold 35 are opposed to each other.

Then, the respective molds are clamped, and in this clamped state, the second resin material is injected into the first mold 31 and the sixth mold 36 to form an opaque portion (second resin member) 3f. , and as shown in FIG. 9, the opaque portion 3f is bonded to the translucent portion 3d to form the lens (second molding member) 3 (secondary molding). Here, the lens 3 is molded by injecting the second resin material so that the non-light-transmitting portions 3f are arranged on both sides of the light-transmitting portion 3d in the direction perpendicular to the extending direction P of the lens 3. In the lens 3, as shown in FIG. 3, a portion of the outer peripheral portion 3c of the translucent portion 3d and a portion of the outer peripheral portion 3g of the opaque portion 3f are butted and joined.

After the lens 3 is molded, the molds are opened while the housing 2 is held by the second mold 32 and the lens 3 is held by the sixth mold 36 . Then, in this mold-opened state, sealing members such as the inner lens member 5, the substrate 6 and the sub-substrate 6b are attached to the accommodating portion 2a of the housing 2 held by the second mold 32 as shown in FIG. . An LED (light emitting element) 8 is mounted on the sub-board 6b.

After mounting the encapsulating member, the rotary table 11 is rotated in a predetermined direction, for example, 120° counterclockwise while the molds are opened, so that the first mold 31 and the fifth mold 35 are formed as shown in FIG. 6(c). , the second mold 32 and the sixth mold 36, and the third mold 33 and the fourth mold 34, respectively.

Furthermore, each mold is clamped. At this time, the second mold 32 holds the housing 2 and the sixth mold 36 holds the lens 3 . A third resin material is injected into the second mold 32 and the sixth mold 36 while the molds are clamped, and the housing 2 and the lens 3 are joined with the third resin material. Here, as shown in FIG. 10, the lamp 1 is molded by bonding the housing 2 and the lens 3 with a resin bonding material (third resin material, third resin member) 9 (third molding).

Incidentally, in the bonding of the housing 2 and the lens 3, the third resin material is used to form a pre-cured resin bonding material 9, the resin bonding material 9 is assembled to the housing 2, and the assembled resin bonding material is The lamp 1 may be formed by joining the housing 2 and the lens 3 by melting the material 9 .

After joining the housing 2 and the lens 3 , each mold is opened and the lamp 1 is taken out from the second mold 32 and the sixth mold 36 . Then, with the molds opened, the rotary table 11 is rotated in a predetermined direction, for example, 120° counterclockwise to form a first mold 31, a fourth mold 34, and a second mold as shown in FIG. 6(a). 32 and fifth mold 35, and third mold 33 and sixth mold 36 are opposed to each other. That is, the rotary table 11 is returned to the initial position.

In the assembly of the lamp 1 of the present embodiment, the rotary table 11 is rotated by 120° and is rotated by 360° while injection molding is performed at every 120° position. It is possible to mold the housing 2, mold the opaque portion 3f of the lens 3 by secondary molding (lens molding), and bond the housing 2 and the lens 3 by tertiary molding.

As a result, the molding of the housing 2 and the lens 3 and the joining of the housing 2 and the lens 3 can be processed by a single injection molding apparatus 10, so the inventory of moldings such as the housing 2 and the lens 3 can be reduced. The lamp 1 can be manufactured without generating That is, by using the injection molding apparatus 10 of the present embodiment, it is possible to assemble the lamp 1 without inventory.

As a result, since there is no inventory of the housing 2 and the lens 3, there is no need to manage the inventory of the housing 2 and the lens 3, and the efficiency of assembling the lamp 1 can be improved.

In addition, it is possible to eliminate the need for a storage space for molded products for stocking the housing 2 and the lenses 3, and to effectively utilize the work space in the area where injection molding is performed.

It goes without saying that the present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the gist of the present invention. For example, in the above-described embodiment, the case where the lamp 1 is taken out after opening the mold at the injection position where the tertiary molding, which is the joining of the housing 2 and the lens 3, is performed, but the tertiary molding is performed. The lamp 1 may not be removed from the injection position, and the rotary table 11 may be rotated counterclockwise by 120° and returned to the initial position, after which the mold is opened and the lamp 1 may be removed from the mold.

Further, the injection-molded article of the above-described embodiment may be a lamp or the like that is attached to a place other than the mirror device of the automobile.

1 lamp (injection molding)
2 housing (first molded member)
2a housing portion 2d wall portion 2e bottom portion 2g outer peripheral portion 2h end surface 3 lens (second molded member)
3a ceiling wall 3b wall portion 3c outer peripheral portion 3d translucent portion (first resin member)
3e end surface 3f opaque portion (second resin member)
3g outer peripheral portion 3j, 3k fitting portion 4 joining portion 5 inner lens member (light guide lens)
6 substrate 6a wiring 6b sub substrate 7 terminal 8 LED (light emitting element)
9 Resin bonding material (third resin material, third resin member)
REFERENCE SIGNS LIST 10 injection molding device 11 rotary table 12 first injection device 12a injection cylinder 12b injection opening 13 second injection device 13a injection cylinder 13b injection opening 14 third injection device 14a injection cylinder 14b injection opening 15 fixing plate 16 positioning pin 20 mirror device 21 Main cover 22 Low cover 23, 24 Stay cover 25 Body 25a Visible part 26 Mirror 27 Stay bracket 28, 29 Wind noise countermeasure member 31 First mold 32 Second mold 33 Third mold 34 Fourth mold 35 Fifth mold Mold 36 6th mold

Claims (4)

a rotary table; first, second and third molds arranged on the rotary table at predetermined intervals along the direction of rotation of the rotary table; A method for manufacturing an injection molded body using an injection molding apparatus comprising fourth, fifth and sixth molds for mold opening and mold clamping,
(a) clamping the first and fourth molds facing each other and injecting a first resin material into the clamped first and fourth molds to form a first resin member; ,
(b) clamping the second and fifth molds facing each other, and injecting a second resin material into the clamped second and fifth molds to form a first molded member; ,
(c) each mold is opened while the first mold is holding the first resin member and the second mold is holding the first molding member, and the mold is opened; rotating the rotary table in a predetermined direction to face the first and sixth molds, the second and fourth molds, and the third and fifth molds;
(d) clamping each mold, injecting the second resin material into the first and sixth molds in the clamped state to mold a second resin member, and forming the second resin member; to the first resin member to form a second molded member;
(e) Each mold is opened with the first molding member held by the second mold and the second molding member held by the sixth mold, and the mold is opened. rotating the rotary table in the predetermined direction to face the first and fifth molds, the second and sixth molds, and the third and fourth molds;
(f) clamping the respective molds, injecting a third resin material into the second and sixth molds in the clamped state, and 2 joining the molded members;
A method for producing an injection molded article, comprising: In the step (a), a translucent material is injected as the first resin material, and in the step (d), a non-translucent material is injected as the second resin material. The method for producing an injection molded article according to claim 1. In the step (f), a third resin member is molded from the third resin material, the third resin member is assembled with the first molding member, and the first molding member and the first molding member are assembled together by the third resin member. 3. A method for producing an injection molded article according to claim 1, wherein the second molded member is joined. After the step (b) and before the step (f), a step of attaching a light emitting element and a light guide lens for guiding light emitted from the light emitting element to the first molding member is performed. The method for manufacturing an injection molded article according to any one of claims 1 to 3, characterized in that:

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