JP4424070B2 - Insert product molding device, electromagnetic device, discharge lamp lighting device, lighting fixture, and vehicle - Google Patents

Description

The present invention Inserts article molding apparatus, an electromagnetic device, a discharge lamp lighting device, lighting fixture, and to a vehicle.

  Traditionally, circuit components such as transformers and ICs require insulation and waterproofing, so the surface was covered with a potting material to ensure insulation and waterproofing. The improvement in properties has been strongly demanded, and the surface has been sealed with a molding resin. For this resin sealing, an insert product molding method used in injection molding or transfer molding excellent in mass productivity is employed. For example, an insert product molding method as shown in Patent Document 1 is performed.

In the insert product molding method disclosed in the above document, while the insert product is held in the cavity by a holding member provided so as to be movable forward and backward with respect to the mold cavity, molten resin is injected into the cavity, The holding member is retracted from the cavity before or after the filling of the molten resin is completed, and the insert product is sealed with resin, but the holding member is in contact with the molten resin so that the holding member can be retracted. The surface of the member is heated by a heating means to prevent the molten resin near the holding member from being cured. That is, by heating the holding member using a heating means, a cooling solidified layer is not formed even when the molten resin filled in the cavity contacts the holding member, or even if a cooling solidified layer is formed, the degree of cooling Compared to when not heating. Therefore, even if the holding member is retracted from the cavity after the filling of the molten resin is completed, the molten resin flows into the space formed after the holding member is retracted and is surely fused, so that the above space can be sufficiently embedded. Therefore, it is possible to sufficiently suppress the remaining unfused portion. In addition, by holding the insert product with the holding member until the filling of the molten resin is completed, it is possible to prevent the displacement of the insert product, and therefore the position of the insert product and the unfused portion that is formed after the holding member is retracted. It was possible to form a good resin molded product in which the insert was sufficiently sealed while suppressing the residue.
Japanese Patent No. 3389775

  In the insert product molding method described above, the holding member is heated by heating means so that the molten resin that contacts the holding member is not cured, and this heating means is provided inside the holding member and outside the holding member. There are cases where the holding member is heated by heat conduction, but in any case, it is necessary to incorporate a heating means in the molding die, so in order to avoid interference between other structural parts of the molding die and the heating means There has been a problem that the manufacturing cost of the mold rises because the structure of the molding mold becomes complicated or large. Furthermore, when the heating member is provided inside the holding member, there is a problem that the holding member becomes large, and when a heating element that generates heat by energization is incorporated, it is difficult to route the wiring to the heating means through the inside of the mold, Since the wiring also moves in accordance with the advancement and retraction of the holding member, there is a problem that the wiring easily breaks when used for a long period of time, and the power consumption of the heating means increases.

  In addition, since the heat of the heating means for heating the holding member is conducted to the structural parts of the molding die other than the holding member and the molten resin filled in the cavity, these temperatures rise and the molten resin is cooled. It took a long time to reduce productivity. As shown in Table 1 of Patent Document 1, it is conceivable to shorten the time required for heating and cooling the holding member by reducing the heat capacity of the holding member and using rapid heating means. There is a limit to shortening the length, and the molding cycle is lengthened, which hinders productivity. In addition, when a resin having a high melting temperature such as super engineering plastic is used as the molten resin (for example, in the case of polyetherimide, the melting temperature is 400 ° C.), it takes a long time for the holding member to reach the melting point and the glass transition point. There was a problem that productivity was lowered.

  Furthermore, when the insert product held by the holding member is made of a material having low heat resistance such as a general-purpose resin, the insert product is held even if the holding member heated by the heating means contacts the insert product for a short time. There is a problem that the positioning accuracy of the insert product is lowered due to deformation of the member due to heat.

  Also, when the cavity is filled with molten resin, the molten resin that contacts the holding member is warmed by the heat of the holding member, the viscosity decreases, and flows into the sliding part for the holding member to advance and retreat by the molding pressure, cooling There was a possibility that the holding member could not be slid due to solidification. As described above, when the holding member is heated to delay the solidification of the molten resin in the vicinity of the holding member, various problems occur due to the use of the heating means. Therefore, the holding member is not heated. It is desired to delay the solidification of the nearby molten resin.

The present invention has been made in view of the above-mentioned problems, and the object of the present invention is to provide a position shift of the insert product without heating the holding member, or an unfused portion formed after the holding member is retracted from the cavity. residual Inserts article molding apparatus capable of suppressing the electromagnetic device, a discharge lamp lighting device is to provide lighting equipment, and vehicles.

The invention of claim 1 includes a mold multiple, a cavity is formed to match a plurality of molds, is movably disposed within a round hole provided in communication with the cavity in the mold, the cavity And a rod-shaped holding member for holding the insert product, and means for filling the cavity with molten resin while holding the insert product in the cavity by the holding member, and melting at least a part of the insert product Means for retracting the holding member from the cavity at the timing when the resin is encased, and means for filling the space formed by the holding member retracting from the cavity with molten resin . D-cut portion formed in semicircular cross-section by cutting the semi-circular portion is provided, the space available in the relevant D-cut portion and the round hole, the molten resin Characterized in that that the gate is provided.

According to a second aspect of the present invention, in the first aspect of the invention, in the surface portion of the molten resin that comes into contact with the surface of the mold, a hardening acceleration region is provided in which the hardening of the molten resin is promoted more than the surface portion around the holding member. It is characterized by that.

The invention of claim 3 is the invention of claim 2 , wherein the thickness of the resin portion between the curing acceleration region and the insert product is greater than the thickness of the resin portion between the surface portion around the holding member and the insert product. It is also characterized by being made thinner.
A fourth aspect of the invention is characterized in that, in any one of the first to third aspects of the invention, the holding member is disposed so as to freely advance and retract on the mating surfaces of the plurality of molds.

The invention of claim 5, ferrite core, a winding structure and a coil terminal electrically connected to both ends of those the ferrite core to the windings to be wound, and winding, the winding structure the body and insert article is molded using an insert article molding apparatus according to any one of claims 1 to 4, coils sealing resin portion for resin sealing while exposing at least a portion of the terminal characterized by comprising and.

The invention of claim 6 uses the electromagnetic device according to claim 5 .

The invention of claim 7, characterized by using the discharge lamp lighting device according to claim 6, wherein.

The invention of claim 8 is characterized in that the lighting apparatus of claim 7 is used.

According to the first aspect of the present invention, when the molten resin is filled in the cavity, the molten resin is filled from the gate provided at a part of the portion where the holding member slides in the mold. The molten resin always flows in the vicinity of the sliding part, and compared with the molten resin filled in the other part in the cavity, the hardening of the molten resin is delayed in the vicinity of the part where the holding member slides. Can do. Therefore, if the holding member is retracted from the cavity at the timing when the molten resin encloses at least part of the insert product, the molten resin enclosing the insert product is hardened, so that the insert product can be positioned reliably. In addition, the space formed after the holding member is retracted is filled with the molten resin from the gate provided at a part of the portion where the holding member slides, so that the occurrence of an unfused portion of the molten resin can be suppressed. It is possible to provide an insert product molding apparatus that can reliably position the insert product and suppress the occurrence of an unfused portion of the molten resin without providing means for heating the holding member.

According to the second aspect of the present invention, in the surface portion of the molten resin that contacts the surface of the mold, the curing of the molten resin is promoted more in the curing acceleration region than in the surface portion around the holding member. Even when the molten resin in the peripheral region of the holding member is not cured at the timing of the curing, since the molten resin in the curing acceleration region has been cured, the position shift of the insert product can be further suppressed.

According to the invention of claim 3 , by setting the thickness of the resin portion in the curing acceleration region to be thinner than the thickness of the resin portion in the peripheral region, the curing speed of the resin in the curing acceleration region is increased. The curing speed can be increased, and the same effect as that of the invention of claim 2 can be obtained.
According to the invention of claim 4, since the holding member is held on the mating surfaces of the plurality of molds so as to be able to advance and retreat, the degree of freedom in designing the gate position provided in a part of the portion where the holding member moves can be increased. .

According to the invention of claim 5 , by suppressing the displacement of the winding structure that is an insert product, there is no portion where the thickness of the sealing resin that seals the winding structure becomes extremely thin, A desired dielectric breakdown strength can be obtained, and an electromagnetic device with improved insulation can be provided.

According to the invention of claim 6 , by using an electromagnetic device with improved insulation, even if a high voltage generated when the discharge lamp is turned on is applied to the electromagnetic device, the electromagnetic device does not cause dielectric breakdown and is stable. It is possible to provide a discharge lamp lighting device capable of obtaining the lit state.

According to the invention of claim 7 , by using the discharge lamp lighting device of claim 6 , a highly reliable lighting apparatus can be provided.

According to the invention of claim 8 , by using the lighting fixture of claim 7 , a vehicle equipped with a reliable lighting fixture can be provided.

  Hereinafter, an embodiment of an insert product forming apparatus using the insert product forming method according to the present invention will be described with reference to the drawings.

  First, an electromagnetic device using a winding structure (insert product) manufactured by the insert product molding apparatus of this embodiment will be described with reference to FIGS. 17 and 18. An insert product 1 shown in FIG. 17 includes a rod-shaped rod-shaped ferrite core 2, a secondary winding 3 formed by winding a rectangular wire around the ferrite core 2 with one layer edgewise, and a secondary winding. A core holder 4 that holds a ferrite core 2 around which a wire 3 is wound. Terminals 5a and 5b that are electrically and mechanically connected to both ends 3a and 3b of the secondary winding 3 are press-fitted into the core holder 4 Alternatively, they are fixed by simultaneous molding. The insert product 1 is resin-sealed with a sealing resin for insulation to form a molded product (high-voltage circuit block 7).

  In the present embodiment, the winding structure is described as an example of the insert product 1. However, the insert product 1 is not intended to be limited to the winding structure, and the electricity embedded in the sealing resin 6 after molding. Any component can be used. In addition, even when an electrical component is embedded in the sealing resin 6, it goes without saying that the terminals 5a and 5b for electrical connection with the outside and portions having no functional problem may be partially exposed. In the insert 1 shown in FIG. 17, it is necessary to completely seal the high-pressure end of the ferrite core 2 with a sealing resin in order to ensure insulation performance, but the low-pressure end is exposed from the sealing resin. There is no functional problem even if it is allowed.

  Next, an insert product forming apparatus for manufacturing the insert product 1 will be described with reference to FIG. The insert product 1 is molded using two molds 20 and 30, and both molds 20 and 30 are respectively upper molds provided in a mold clamping part (not described in detail) of a conventionally known molding machine 60. The platen 61 and the lower mold platen 62 are attached. One mold 20 includes an upper mold 21, a runner plate 22, and an upper mold mounting plate 23 as main components, and the other mold 30 includes a lower mold 31, a lower mold receiving plate 32, and a lower mold mounting. A plate 33 and a slide core 34 are provided as main components. The molds 20 and 30 are temperature adjusted by temperature adjusting means (fluid circulation, heater, etc.) not shown.

  Cavities 41a and 41b are formed on the mating surfaces of the upper mold 21 and the lower mold 31, respectively, and the insert product 1 is held inside from the two cavities 41a and 41b. A cavity 41 for forming a molded product (high-voltage circuit block 7) by sealing the resin with molten resin 6 is formed. Further, core accommodating recesses 21a and 31a communicating with the cavities 41a and 41b are formed on the mating surfaces of the upper mold 21 and the lower mold 31, respectively. A slide core 34 is slidably disposed in the space that can be formed. FIG. 2 is a cross-sectional view schematically showing the insert 1 described in FIG. 17, in which the terminals 5a and 5b are omitted, and in the following description of the molding method, the schematic structure shown in FIG. The explanation will be given. 2 is shown upside down from FIG. 17, and is held in the cavity 41 in this state. Further, reference numeral 9 in FIG. 2 denotes a high pressure yoke held by the core holder 4.

  Further, on the mating surfaces of the upper mold 21 and the lower mold 31, semi-circular recessed grooves 21b and 31b communicating with the cavities 41a and 41b are formed. The holding member 50 is slidably disposed in a round hole formed by combining the sliding grooves 21b and 31b during alignment. As shown in FIG. 3, the holding member 50 is formed of an elongated round bar, and a flange 52 provided on one end side in the axial direction is connected to the tip of the rod 54 of the air cylinder 53 so as to move back and forth by the air cylinder 53. It has become. And the tip side (cavity part 41 side) from the axial direction intermediate part of the holding member 50 cuts an upper semicircle part, is formed in the cross-sectional semicircle, and the cut semicircle part (this semicircle part) Is referred to as a D-cut portion 51) and a space formed by the sliding grooves 21b and 31b, the outlet of the gate 26 faces, and a flow for introducing the molten resin that has passed through the gate 26 into the cavity portion 41 is provided. It becomes a road. Note that the holding member 50 may have a square bar shape, or the holding member 50 may be driven by a hydraulic cylinder or a motor.

  Here, the molten resin melted at the injection portion (not shown) of the molding machine 60 is fed from the molding machine nozzle 63 to the upper die mounting plate 23 and the runner plate 22 through the sprue 24 and the upper die. The upper mold 21 and the lower mold 31 are passed through a runner 25 and a gate 26 formed in 21 and through a space formed by the D cut portion 51 of the holding member 50 and the sliding grooves 21b and 31b. It is introduced into the cavity 41 formed on the mating surface. In this embodiment, the case of injection molding is shown, but the present invention can also be applied to a molding method such as a transfer molding machine. Moreover, although this embodiment showed the case of the vertical type | molding machine, it cannot be overemphasized that it is applicable also in the case of a horizontal type.

  Hereinafter, an insert product molding method in which the insert product 1 is sealed with a molten resin using the insert product molding apparatus will be described with reference to FIGS. 4 to 11. 4 to 11, the upper mold platen 61, the lower mold platen 62, the molding machine nozzle 63, and the air cylinder 53 are omitted in order to simplify the description.

  First, as shown in FIG. 4, the insert 1 is placed in the cavity 41 b of the mold 30 in a state where the mold 20 is lifted upward. At this time, the temporary holding members 55 and 56 are raised, and the tips thereof are in contact with the winding 3 and the high voltage yoke 9 of the insert 1, and the core holding portion 31 c provided in the lower mold 31 is the ferrite core 2. The insert product 1 is temporarily held in contact with the low-pressure side end portion. The temporary holding member 55 includes a pin having a head portion 55b provided at the lower end of the shaft portion 55a, and is supported by the return plates 35a and 35b by sandwiching the head portion 55b between the two return plates 35a and 35b. ing. The return plates 35a and 35b are disposed in a recess 32a provided in the lower mold receiving plate 32 so as to be movable up and down, and are biased upward by springs 36 and 36, whereby the temporary holding member 55 moves upward. ing. The temporary holding member 56 also includes a pin having a head portion 56b provided at the lower end of the shaft portion 56a. The temporary holding member 56 is disposed so as to be movable up and down with the head portion 56b placed in a recess provided in the lower mold 31. The spring 37 is biased upward by the spring force. The holding member 50 is moved to a position retracted from the cavity portion 41 by the air cylinder 53. In FIG. 4, a lower return pin 38 and a holding member 50, which will be described later, are shown in an overlapping manner. However, they do not interfere with each other, and actually these two parts exist on the same cross section. Not done.

  Next, as shown in FIG. 5, when the upper mold 21 is lowered by a mold opening / closing device (not shown) of the molding machine and the upper mold 21 and the lower mold 31 are closed, the slide core 34 is inclined. When the surface 34 a hits the contact portion 21 c provided on the upper mold 21, the slide core 34 advances to the cavity portion 41 side and contacts the tip surface of the ferrite core 2 on the low pressure side. At the same time, since the core holding portions 21d and 31c provided in the upper mold 21 and the lower mold 31 respectively hold the peripheral surface of the ferrite core 2 from both the upper and lower sides, the ferrite core 2 (that is, the insert product) The end on the low pressure side of 1) is held with high accuracy. The slide core 34 may be moved forward and backward using an actuator such as an air cylinder as in the holding member 50.

  When the proximity switch SW incorporated in the lower mold 31 detects that the upper mold 21 and the lower mold 31 are closed, a control unit (not shown) activates the air cylinder 53 according to the detection signal of the proximity switch SW. Since the rod 54 is driven to advance, the holding member 50 connected to the tip of the rod 54 advances into the cavity portion 41 as shown in FIG. 6 and is provided at the high-pressure side end portion of the ferrite core 2. Engage with the recess 2a to hold the insert 1 completely.

  When the rod 54 of the air cylinder 53 moves forward and the limit switch (not shown) of the air cylinder 53 detects the forward limit, the mold closing is started again by the mold opening / closing device of the molding machine, and the upper mold as shown in FIG. The runner plate 22 comes into contact with the mold 21 to complete the mold closing. At this time, the upper die return pin 27 attached to the runner plate 22 pushes down the lower die return pin 38 attached so as to be sandwiched between the return plates 35a and 35b in the same manner as the temporary holding member 55. 35b descends against the spring force, and the temporary holding member 55 also descends and retracts from the cavity portion 41 accordingly, so that the temporary holding by the temporary holding member 55 ends. At this time, since the holding member 50 is engaged with the engagement recess 2a of the insert product 1, the position of the insert product 1 does not shift.

  Thus, before the holding member 50 moves forward and holds the insert product 1, the insert product 1 is temporarily held by the temporary holding member 55, and the emphasis of the molten resin is applied after the holding member 50 holds the insert product 1. Until the completion, the temporary holding member 55 is retracted from the cavity portion 41, so that the insert product 1 temporarily held by the holding member 40 can be easily held, and the positioning accuracy of the insert product 1 is further increased. improves. Further, since the temporary holding member 55 is retracted from the cavity portion 41 by applying a driving force by the mold clamping operation, it is not necessary to prepare a separate driving source, and from the cavity portion 41 until the filling of the molten resin is completed. Since it is made to retreat, the molten resin surely enters the space from which the temporary holding member 55 is removed, and the non-fusion portion does not remain.

  When the clamping is completed and the clamping is completed by the clamping force of the molding machine, the resin material (molten resin 6) melted from the molding machine nozzle 63 passes through the sprue 24, the runner 25, and the gate 26 as shown in FIG. 41 is filled. Note that the molten resin 6 used in the present embodiment is polypropylene, polyethylene having a low thermoplastic melting temperature, polyphthalamide having a high melting temperature, polyetherimide, liquid crystal polyester, syndiotactic polystyrene, thermosetting phenol, Various resin materials such as epoxy and unsaturated polyester can be used. Here, a means for filling the molten resin is formed from the molding machine nozzle 63 of the molding machine.

  At this time, since the spring force of the spring 37 that biases the temporary holding member 56 upward is set smaller than the resin pressure in the cavity portion 41, the temporary holding member 56 is lowered by the resin pressure, and the cavity portion 41. Therefore, the temporary holding by the temporary holding member 56 ends. Since the temporary holding member 56 moves backward due to the resin pressure in this way, the positioning accuracy of the insert product 1 is improved without requiring a separate drive source and by temporarily holding it before the holding member 50 holds it. Can be made.

  Although the outlet of the gate 26 is opened so as to face the D-cut portion 51 of the holding member 50, the holding member 50 can freely advance and retreat on the mating surface of the upper mold 21 and the lower mold 31. Therefore, the design of the flow path from the molding machine nozzle 63 to the gate 26 can be optimized, and the fluidity in the periphery of the holding member 50 is greatly reduced. It is possible to supply the molten resin 6 which has not been performed. Needless to say, the gate 26 may be provided in addition to the sliding portion to form a multipoint gate.

  After that, before completion of filling the molten resin 6 into the cavity part 41 or after completion of filling, the control unit detects the predetermined timing when the molten resin 6 encloses at least a part of the periphery of the insert product 1 and the control unit When the cylinder 53 is driven and the rod 54 is retracted, the holding member 50 is retracted from the cavity portion 41. Here, means for retracting the holding member from the air cylinder 53 is configured, but it goes without saying that an actuator such as a hydraulic cylinder or a motor other than the air cylinder may be used.

  If the molten resin 6 is filled in this way, the molten resin 6 is always supplied from the molding machine in the vicinity of the gate 26, that is, in the vicinity of the holding member 50. Curing will be delayed. Accordingly, when the holding member 50 is moved backward, the insert product 1 is reliably positioned by the solidification of the molten resin 6 filled in other parts, and the space formed after the holding member 50 moves backward is melted. Since the resin 6 flows in and this space can be reliably filled, it is possible to obtain a good resin molded product in which the insert product 1 is sufficiently sealed while suppressing the unfused portion from remaining. Here, as the predetermined timing described above, the timing of detecting the position of the screw of the screw type molding machine, the time when the injection pressure of the molding machine or the internal pressure of the mold reaches a predetermined value, or a predetermined time has elapsed since the start of injection. It is possible to use a point in time or a combination of these. Note that the holding member 50 may be retracted after the filling of the molten resin, and the positioning accuracy of the insert 1 is further improved.

  Further, in this embodiment, raised portions 21e and 31d are formed in the molds 21 and 31 near the flow end in the cavity portion 41, and the thickness of the resin portion in this portion is smaller than that in the peripheral region of the holding member 50. By providing the thin portion 7a, solidification or curing of the molten resin 6 is promoted only by the thin portion 7a (this thin portion 7a becomes a hardening promoting region), while the molten resin 6 filled in the peripheral region of the holding member 50 is provided. Since it is still in a molten state, the timing for retracting the holding member 50 can be further delayed, and the misalignment of the insert product 1 can be prevented while the unfused portion remains. The thickness of the thin portion 7a (curing acceleration region) is about 0.5 mm to 1.0 mm, and the thickness of the resin portion other than the thin portion 7a is about 2.0 to 4.0 mm, but is not necessarily limited to this range. Is not to be done. In the present embodiment, the raised portions 21e and 31d are formed on the molds 21 and 31, but by providing the raised portions on the insert product 1 side, the same effect as described above can be obtained even when a thin portion is formed. .

  Thereafter, when the time required for the molten resin 6 filled in the cavity portion 41 to sufficiently solidify or harden has elapsed by setting the timer of the molding machine, the mold 20 is raised by the mold opening / closing device of the molding machine as shown in FIG. The two molds 20 and 30 are opened. At this time, the slide core 34 is not pressed forward by the contact portion 21 c of the upper mold 21, so that the slide core 34 is retracted by a spring for retracting the slide core (not shown) and separated from the end face of the ferrite core 2. Further, the holding member 50 is retracted by the air cylinder 53, but a conical protrusion is provided at the tip of the holding member 50 so as to be in close contact with the mortar-shaped engaging recess 2 a provided on the ferrite core 2. Since the undercut 7b that interferes with the holding member 50 is formed when the molded product (the high-voltage circuit block 7) is released upward, the holding member 50 is prevented from being caught by the undercut 7b of the molded product. It is further retracted.

  When the retracting of the holding member 50 is completed, the extrusion device (not shown) of the molding machine is driven as shown in FIG. 11, and the molded product (high voltage circuit block) is ejected by the ejector pins (not shown) in the mold 30. 7) can be protruded from the lower mold 31 and taken out.

  In the above-described insert product molding method, the holding member 50 is moved forward after the upper mold 21 and the lower mold 31 are combined, and the insert product 1 is held. Depending on the accuracy, as shown in FIGS. 16A to 16C, the holding member 50 is advanced before the mold is closed, and the tip of the holding member 50 is engaged with the engaging recess 2 a of the ferrite core 2. Later, mold clamping may be performed.

As described above, in the insert product molding method of the present embodiment, the holding member is disposed so as to be movable forward and backward with respect to the cavity portion 41 formed by combining a plurality of (two in the present embodiment) molds 20 and 30. A step of holding the insert product 1 in the cavity portion 41 by 50, a step of filling the cavity portion 41 with the molten resin 6 in a state where the insert product 1 is held by the holding member 50, and at least a part of the insert product 1 In an insert product molding method including a step of retracting the holding member 50 from the cavity portion 41 at a timing when the molten resin 6 is enclosed, and a step of filling the space formed after the holding member 50 has retracted from the cavity portion with the molten resin 6. ,
The molten resin 6 is filled into the cavity 41 from the gate 26 provided at a part of the sliding portion (consisting of the sliding grooves 21b and 31b) in which the holding member 50 slides in the molds 21 and 31, thereby holding the holding member. Although the solidification or hardening of the molten resin 6 near 50 is delayed, the molten resin 6 is surely flowed into the space formed after the holding member 50 is retracted to suppress the occurrence of an unfused portion. In order to verify the effect of providing the gate 26 at the 50 sliding portions, the solidification rate of the molten resin 6 in the vicinity of the holding member 50 at the completion of the filling of the molten resin 6 was obtained by calculation using flow analysis. Arrows G1 to G4 in FIGS. 12 (a) to 12 (e) indicate gate position conditions for determining the solidification rate of the molten resin 6, and as shown in FIGS. 12 (a) to (c), the holding member 50 is provided. When the gate G1 is provided at the sliding portion, the solidification rate of the molten resin 6 in the vicinity of the holding member 50 (F portion in the drawing) at the completion of filling is about 50%, whereas FIG. ) When the gates G2 to G4 are provided in addition to the sliding portion of the holding member 50 as shown in (e), the solidification rate is 70% even when the gate G4 is provided on the side close to the holding member 50. It can be seen that providing a gate at the sliding portion of the holding member 50 is effective in reducing the solidification rate of the molten resin in the vicinity of the holding member 50 (that is, delaying solidification).

  Further, the significance of providing a gate at the sliding portion of the holding member 50 was verified with further data. When the gate G1 is provided at the sliding portion of the holding member 50 as shown in FIG. 13 (a) and when the mold faces the portion of the molded product 7 close to the holding member 50 as shown in FIG. 13 (b). FIG. 14 shows the results of determining the change with time from the start of filling of the resin temperature of the molten resin 6 (for example, polyphthalamide) in the vicinity of the holding member 50 when the gate G4 is provided at the site. In the figure, “A” indicates the change with time when the gate G1 is provided, and “B” indicates the change with time when the gate G4 is provided. The resin temperature is 310 ° C. (the temperature at which the molten resin 6 does not flow) from the start of filling. The time to descend is about 3 seconds in the case of the gate G4, whereas it is about 12 seconds in the case of the gate G1, and the holding is achieved by providing the gate G1 at the sliding portion of the holding member 50. The time during which the resin temperature of the molten resin 6 in the vicinity of the member 50 falls can be delayed, and the timing for retracting the holding member 50 can be delayed.

  In more detailed verification, when the gate G1 is provided at the sliding portion of the holding member 50 as shown in FIG. 13A, each part of the molded product (near the holding member 50 (P1 in FIG. 8)), FIG. 15 shows the results obtained by determining the change over time of the resin temperature of the molten resin 6 (for example, polyphthalamide) at the thin wall portion (P3 in FIG. 8) and the flow end (P2 in FIG. 8) from the start of filling. In the figure, a is a temperature change in the vicinity (P1) of the holding member, b is a temperature change in the thin portion (P3), and c is a temperature change in the flow end (P2). From the calculation result of FIG. 15, the time until the average resin temperature in the thickness direction falls to 310 ° C. (the temperature at which the molten resin 6 does not flow) is about 1 second at the flow end, whereas the holding member 50 In the vicinity, the delay was about 12 seconds. Further, it takes about 4 seconds from the time when the resin temperature of the thin portion 7a is lowered to 310 ° C. until the temperature of the resin in the vicinity of the holding member 50 is lowered to 310 ° C. The timing for retracting the holding member 50 can be set during this time. Is possible.

  By the way, the above-mentioned insert product 1 is a winding structure, and the position shift of the winding structure can be suppressed by using the above-described insert product molding method. Since there is no portion where the thickness of the resin becomes extremely thin, a desired dielectric breakdown strength can be obtained, and an electromagnetic device with improved insulation can be provided. The insert 1 described above is used in a discharge lamp starting device A that applies a high-pressure pulse to a discharge lamp in order to start a discharge lamp such as a metal halide lamp, and a discharge lamp using the discharge lamp starting device A is used. A circuit diagram of the lamp lighting device is shown in FIG. The discharge lamp starting device A is configured by winding a primary winding 8 around the outer periphery of the low-pressure side end of the high-voltage circuit block 7 described above, and one end of the secondary winding 3 is connected to one electrode of the discharge lamp La. A pulse transformer PT, a discharge gap SG connected in series to the primary winding 8 of the pulse transformer PT, and a capacitor C1 for generating a pulse connected between both ends of a series circuit composed of the primary winding 8 and the discharge gap SG And a bypass capacitor C2 connected between the other end of the secondary winding 3 and the other electrode of the discharge lamp La to form a bypass loop when a pulse is generated. When the capacitor C1 is charged by the inverter circuit INV and the voltage across the capacitor C1 reaches a predetermined voltage, the discharge gap SG is discharged and a current flows through the primary winding 8 of the pulse transformer PT. At this time, a high-pressure pulse is generated in the secondary winding 3 of the pulse transformer PT, and this high-pressure pulse is applied to the discharge lamp La to start the discharge lamp La and receive power supply from the inverter circuit INV to receive the discharge lamp. La lights up.

  FIG. 18 shows each manufacturing process of the discharge lamp starting device A. As shown in FIG. 18A, capacitors C1 and C2, a discharge gap SG, and an inverter circuit are formed on a substrate 11 made of a printed wiring board or a lead frame. The low-voltage circuit block 12 is configured by mounting the connector CN to the INV, and the outer peripheral surface of the low-voltage side end of the high-voltage circuit block 7 (that is, the surface of the sealing resin covering the low-voltage side end of the ferrite core 2). The primary winding 8 is wound to constitute the pulse transformer PT, and the inner electrode 14 is electrically connected to the socket electrode 13 provided integrally with the high voltage circuit block 7 to the center electrode and the outer peripheral electrode of the discharge lamp La, respectively. The outer electrode 15 is held. Then, after mounting the high-voltage circuit block 7 on the substrate 11 of the low-voltage circuit block 12 as shown in FIG. 4B, the upper surface cover 16 and the lower surface cover 17 made of a synthetic resin molded product are mounted to ensure insulation. Then, the space surrounded by the covers 16 and 17 is partially or entirely filled with an insulating resin such as silicon, and further covered with the upper shield cover 18 and the lower shield cover 19 from both the upper and lower sides to suppress noise, The assembly of the discharge lamp starting device A is completed (see (c) in the same figure). The discharge lamp starting device A is configured as described above. By using the above-described insert 1 having high insulation performance, even when a high voltage is applied at the time of starting the discharge lamp La, dielectric breakdown does not occur. Since no unlighting occurs, a stable lighting state can be obtained. The top cover 16 and the top shield cover 18 are formed with round hole-shaped opening windows 16a and 18a for exposing the socket opening 13, and the cap of the discharge lamp La can be mounted through the opening windows 16a and 18a. ing.

  By the way, the above-described discharge lamp starting device A applies a high-pressure pulse to the discharge lamp La in order to start a discharge lamp La composed of an HID lamp such as a metal halide lamp. This discharge lamp starting device A was used. A block diagram of the discharge lamp lighting device B is shown in FIG. The discharge lamp lighting device B includes an inverter INV that converts a DC voltage of a DC power source E into a rectangular wave voltage and supplies the rectangular wave voltage to a discharge lamp La mounted on the discharge lamp starting device A, and a high-pressure pulse included in the discharge lamp starting device A. The generator is composed of a charging capacitor C1, a bypass capacitor C2, a discharge gap SG, and a pulse transformer PT.

  FIG. 20 shows an embodiment of a vehicle headlamp fixture C using the above-described discharge lamp lighting device B. The headlamp fixture C is placed inside the lamp housing 101 fixed to the vehicle body. The discharge lamp starting device A and the reflecting plate 102 are accommodated, and a lens 103 is attached to an opening provided on the front surface of the lamp housing 101. An opening 104 for replacing the discharge lamp La is provided at the rear of the lamp housing 101, and a cap 105 is attached to the opening 104 so as to be freely opened and closed. Also, an inverter circuit INV that operates by receiving power supply from the DC power source E is attached to the lower portion of the lamp housing 101, and the electric wire 106 from the inverter circuit INV is connected to the connector CN of the discharge lamp starting device A. It is connected. Reference numeral 107 in the figure denotes a connection connector for connecting a power supply line from the DC power source E. The headlamp fixture C is configured using the above-described discharge lamp lighting device B. If the headlamp fixture C is used for a vehicle headlamp, a highly reliable headlamp can be realized. Note that the lighting fixture is not limited to the headlamp C, and the above-described discharge lamp lighting device B may be used to configure a lighting fixture used for a light source of a projector, for example.

  FIG. 21 shows an embodiment of a vehicle D using the above-described vehicle headlamp fixture C. One vehicle headlamp fixture C is attached to each of the left and right sides of the front surface of the vehicle body 110. The vehicle D uses the vehicle headlamp fixture C described above, and by using the highly reliable headlamp fixture C, a vehicle with high safety can be realized during night driving.

It is sectional drawing which can abbreviate | omit a part of insert product shaping | molding apparatus using the insert product shaping | molding method of this embodiment. It is sectional drawing which showed typically the insert goods formed using the same as the above. It is an external appearance perspective view of the holding member used for the same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. It is sectional drawing explaining 1 process of the insert goods shaping | molding method same as the above. (A)-(e) is explanatory drawing explaining the position of a gate. (A) (b) is explanatory drawing explaining the position of a gate. It is the figure which showed the time transition of the resin temperature of the molten resin in the vicinity of a holding member. It is the figure which showed the time transition of the resin temperature of the molten resin in each part of a molded article. (A)-(c) is explanatory drawing of another insert goods shaping | molding method same as the above. It is explanatory drawing of each manufacturing process of the high voltage circuit block formed using the same as the above. It is explanatory drawing of each manufacturing process of the discharge lamp starter using a high voltage circuit block same as the above. It is a block circuit diagram of the discharge lamp lighting device using the same. It is sectional drawing of the vehicle headlamp fixture using the same as the above. It is a principal part perspective view of the vehicle using the same as the above.

Explanation of symbols

21 Upper mold 21b, 31b Sliding groove 26 Gate 31 Lower mold 41 Cavity 50 Holding member

Claims (8)

A plurality of molds , a cavity formed by combining the plurality of molds , and a reciprocating arrangement in a round hole provided in the mold in communication with the cavity, and protruding into the cavity to be inserted together and a holding member of a round bar for holding goods, and means for filling the molten resin into the cavity while holding the insert article within said cavity by said holding member, at least a portion of said insert article and means for retracting the holding member from said cavity at the timing when the molten resin is outerwrap, and means for the retaining member is filled with the molten resin into the space that can by receding from the cavity,
At the tip of the holding member on the cavity side, a D-cut part formed by cutting a semicircular part on one side to have a semicircular cross section is provided, and melted in a space formed by the D-cut part and the round hole. An insert molding apparatus characterized in that a gate for filling resin is provided. The insert product according to claim 1, wherein a hardening acceleration region is provided in the surface portion of the molten resin that contacts the surface of the mold so as to accelerate the hardening of the molten resin more than the surface portion around the holding member. Molding equipment. The insert molding apparatus according to claim 2, wherein the thickness of the molten resin in the curing acceleration region is made thinner than the thickness of the molten resin in the surface portion around the holding member. The insert product forming apparatus according to any one of claims 1 to 3, wherein the holding member is disposed so as to freely advance and retract on a mating surface of a plurality of molds. A winding structure including a ferrite core, a winding wound around the ferrite core, and a coil terminal electrically connected to both ends of the winding, and the winding structure as an insert product. And a sealing resin portion that is molded using the insert product molding device according to any one of claims 4 to 4 and that seals the winding structure with resin in a state where at least a part of the coil terminal is exposed. An electromagnetic device characterized by that. A discharge lamp lighting device using the electromagnetic device according to claim 5. The lighting fixture using the discharge lamp lighting device of Claim 6. A vehicle using the lighting apparatus according to claim 7.

Images