Mold for in-mold injection molding of outer lens

Abstract

The utility model provides a mold for in-mold injection molding of an outer lens. The mold comprises a fixed side main insert and a movable side main insert, a cavity is formed between the fixed side main insert and the movable side main insert, and a diaphragm is arranged in the cavity; a limiting boss is arranged in the cavity, a limiting hole is formed in the diaphragm, the limiting boss is located in the limiting hole, and the limiting boss and the limiting hole are used for limiting and fixing the diaphragm. According to the utility model, the boss is arranged in the area, corresponding to the non-appearance surface of the product, in the upper cavity of the mold, so that the problem that the diaphragm is easy to misplace during placement is solved, the diaphragm can be quickly and reliably placed, and the effects of reducing the operation time and improving the yield are achieved.

Description

Technical Field

[0001] The utility model relates to the technical field of vehicle lamps, in particular to a mold for internal injection molding of an outer lens film, in particular to a mold structure for internal injection molding of an outer lens film of a vehicle lamp. Background Art

[0002] Current headlight outer lenses are injection-molded products made of PC. To meet regulatory requirements, these lenses still require subsequent surface treatments such as hardening and anti-fogging. However, these surface treatments pose significant environmental risks, and with the development of the industry, increasingly stringent requirements for environmental protection are being placed on them. The present invention utilizes an in-mold lamination process to combine the requirements of hardening, anti-fogging, and decoration on a PC or PC+PMMA film. Through a single in-mold lamination injection molding process, the result is a headlight outer lens that complies with regulations without the need for subsequent surface treatment, while also allowing for the addition of decorative elements as needed. In addition, some of the current headlight outer lenses are usually transparent + black two-color double-station injection molding. This injection molding method uses the black part to cover the internal structure of the headlight, achieving both beautiful appearance and light leakage prevention effects, and is well adapted to the current requirements of industrial production. However, this injection molding method of two-color double-station injection molding has a complex structure. The utility model adopts an in-mold film, and the function of the black part can be replaced by black ink printed on the film, so that the mold of the outer lens is simplified from two-color double-station to single-color single-station injection molding, making the mold simpler and reducing costs.

[0003] When using molded-in injection molding for exterior lenses of headlights with varying curved shapes, the basic requirements of limiting and securing the diaphragm need to be addressed. To ensure proper positioning of the diaphragm within the mold, existing mold injection molding processes often require enlarging the diaphragm, placing a portion of the diaphragm outside the cavity, and using the mold clamping force to press the diaphragm tightly into the mold. However, this method has the following limitations: First, the diaphragm may extend beyond the mold cavity, requiring post-processing to trim the excess portion; second, it is only suitable for thinner, softer diaphragms. Using the mold mold of the present invention, the diaphragm can be positioned within the mold cavity, eliminating the need for post-processing. Even thicker diaphragms can be held tightly to the inner surface of the cavity through local engagement and vacuum suction. The present invention incorporates a limiting structure on the mold to facilitate placement of the diaphragm. Furthermore, a protrusion is provided on the other side of the mold so that after mold clamping, the protrusion can firmly press the diaphragm against the cavity surface, preventing unnecessary misalignment and wrinkling of the diaphragm caused by high shear rates during the injection molding phase. Utility Model Content

[0004] In view of the defects in the prior art, the purpose of the present invention is to provide a mold for injection molding of outer lens films.

[0005] According to the utility model, a mold for inner injection molding of an outer lens film is provided, comprising: a fixed side main insert and a movable side main insert;

[0006] A cavity is formed between the fixed-side main insert and the movable-side main insert, and a diaphragm is arranged in the cavity;

[0007] A limiting boss is provided in the mold cavity, a limiting hole is provided on the diaphragm, the limiting boss is located in the limiting hole, and the limiting boss and the limiting hole are used for limiting and fixing the diaphragm.

[0008] Preferably, meshing teeth are provided in the cavity, the meshing teeth abut against the diaphragm, and the meshing teeth are used to limit and fix the diaphragm.

[0009] Preferably, the meshing teeth are provided in plurality, and the plurality of meshing teeth are distributed in the cavity;

[0010] And / or, one or more meshing teeth are distributed around the gate of the mold.

[0011] Preferably, the meshing teeth include one or more connected protruding tooth structures.

[0012] Preferably, the tooth tips of the protruding tooth structure are arranged in an arc shape.

[0013] Preferably, the tooth tips of the protruding tooth structure are arranged in an interference fit with the diaphragm.

[0014] Preferably, a fixed side exhaust insert and a hot runner insert are provided in the fixed side main insert;

[0015] The fixed side exhaust insert and the hot runner insert are both connected to the cavity.

[0016] Preferably, a movable side exhaust insert is provided in the movable side main insert;

[0017] The movable side air extraction insert is connected to the mold cavity.

[0018] Preferably, the movable side exhaust insert is provided with a full circle of exhaust grooves, vacuum pipes and local exhaust grooves;

[0019] The mold cavity, the local exhaust groove, the full circle exhaust groove and the vacuum pipeline are connected in sequence.

[0020] Preferably, the movable side main insert and the movable side exhaust insert are connected and fixed by insert fixing bolts;

[0021] The movable side air extraction insert is provided with a sealing ring groove, and a rubber ring is provided in the sealing ring groove;

[0022] The rubber ring is located between the movable side main insert and the movable side air extraction insert, and the rubber ring is arranged around the insert fixing bolt.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] 1. The utility model realizes injection molding by adopting in-mold film, which provides greater freedom for the production of headlight outer lens, avoids the surface treatment required under the existing process, and can choose more personalized product decoration. It simplifies the two-color and two-station injection molding mold into a single-color and single-station injection mold with mold film technology.

[0025] 2. The utility model solves the problem of easy misalignment of the diaphragm by setting a boss in the area of ​​the non-appearance surface of the product inside the mold cavity, realizes fast and reliable diaphragm placement, and achieves the effect of reducing operation time and improving yield rate.

[0026] 3. The utility model solves the problem that the diaphragm is easily deformed, dislocated and wrinkled by the impact of high-speed, high-temperature and high-pressure fluid on the diaphragm by arranging diaphragm meshing teeth near the gate of the mold, thereby achieving the effect of improving the product yield.

[0027] 4. The utility model solves the problem of loose fit between the visible part of the diaphragm and the cavity wall by arranging a vacuum insert on the cavity wall on the side where the film is pasted, thereby preventing the diaphragm from being dislocated and wrinkled during the injection molding process, thereby achieving the effect of improving appearance quality and yield rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Other features, objects and advantages of the present invention will become more apparent from the detailed description of the non-limiting embodiments with reference to the following drawings:

[0029] Figure 1 This is the assembly diagram of the product and diaphragm;

[0030] Figure 2 for Figure 1 Section along line AA;

[0031] Figure 3 for Figure 2 A partial enlarged view of part C;

[0032] Figure 4 is a cross-sectional view of a mold for inner injection molding of an outer lens film;

[0033] Figure 5 A schematic diagram showing the structure of the fixed side main insert and the fixed side exhaust insert;

[0034] Figure 6To highlight the structural diagram of the meshing teeth;

[0035] Figure 7 for Figure 6 Section along line HH Figure 1 ;

[0036] Figure 8 To highlight the enlarged view of the meshing teeth;

[0037] Figure 9 for Figure 6 Section along line HH Figure 2 ;

[0038] Figure 10 To highlight the structural diagram of the movable side exhaust insert;

[0039] Figure 11 A structural diagram showing the location of the product's non-appearance surfaces;

[0040] Figure 12 A structural diagram showing the assembly relationship between the limiting boss and the limiting hole;

[0041] Figure 13 It is a structural schematic diagram showing the abutment relationship between the protruding tooth structure and the diaphragm.

[0042] The figure shows:

[0043] Product 1 Movable side exhaust insert 8

[0044] Diaphragm 2 Fixed side exhaust insert 9

[0045] Limit hole 201 Hot runner insert 10

[0046] Gate 3 Full circle exhaust groove 11

[0047] Meshing teeth 4 Sealing ring groove 12

[0048] Protruding tooth structure 401 Vacuum pipe 13

[0049] Limiting boss 5 Local exhaust groove 14

[0050] Fixed side main insert 6 cavity 15

[0051] Movable side main insert 7 Insert fixing bolt 16 DETAILED DESCRIPTION

[0052] The present invention will be described in detail below with reference to specific embodiments. The following embodiments will help those skilled in the art further understand the present invention, but are not intended to limit the present invention in any way. It should be noted that a person skilled in the art may make various variations and improvements without departing from the scope of the present invention. Such variations and improvements are all within the scope of protection of the present invention.

[0053] Example 1:

[0054] like Figures 1 to 13 As shown, this embodiment provides a mold for injection molding of an outer lens membrane, including: a fixed side main insert 6 and a movable side main insert 7; a cavity 15 is formed between the fixed side main insert 6 and the movable side main insert 7, and a diaphragm 2 is arranged in the cavity 15; a limiting boss 5 is arranged in the cavity 15, and a limiting hole 201 is arranged on the diaphragm 2, the limiting boss 5 is located in the limiting hole 201, and the limiting boss 5 and the limiting hole 201 are used to limit and fix the diaphragm 2.

[0055] The limiting boss 5 is set on the wall surface of the cavity 15 for contacting the non-appearance surface of the product 1. The setting of the limiting boss 5 will form a pit on the product 1 after the injection molding is completed. Therefore, the limiting boss 5 is set on the wall surface of the cavity 15 for contacting the non-appearance surface of the product 1, so that the pit can be formed on the non-appearance surface of the product 1, avoiding the pit from affecting the appearance of the product 1. Figure 1 As shown, from the main view perspective, the non-appearance surface of product 1 is the rear product surface.

[0056] The non-appearance surface is usually on one side of the product, such as Figure 11 The dotted circle in the figure shows the product 1 to be formed by injection molding. Figure 12 , which is a schematic structural diagram of the assembly of the limiting boss 5 and the limiting hole 201 .

[0057] A fixed-side exhaust insert 9 and a hot runner insert 10 are mounted within the fixed-side main insert 6; both are connected to the mold cavity 15. A movable-side exhaust insert 8 is mounted within the movable-side main insert 7; this insert is connected to the mold cavity 15. The movable-side main insert 7 and the movable-side exhaust insert 8 are connected and fixed by insert fixing bolts 16. A sealing ring groove 12 is provided in the movable-side exhaust insert 8, within which a rubber ring is positioned; the rubber ring is positioned between the movable-side main insert 7 and the movable-side exhaust insert 8, and surrounds the insert fixing bolts 16.

[0058] The cavity 15 is provided with meshing teeth 4, which abut against the diaphragm 2 and are used to limit and fix the diaphragm 2. A plurality of meshing teeth 4 are provided, and the plurality of meshing teeth 4 are distributed within the cavity 15; one or more meshing teeth 4 are distributed around the gate 3 of the mold. The meshing teeth 4 include one or more connected protruding tooth structures 401. The tooth tips of the protruding tooth structures 401 are arranged in an arc shape. In this embodiment, the tooth tips of the protruding tooth structures 401 are arranged in a hemispherical shape with a radius of 0.5 mm. The tooth tips of the protruding tooth structures 401 are arranged in an interference fit with the diaphragm 2.

[0059] In this embodiment, the meshing teeth 4 include two connected protruding tooth structures 401. The meshing teeth 4 are disposed on the wall of the mold cavity 15 opposite the diaphragm 2. The meshing teeth 4 are disposed on the wall of the mold cavity 15 that contacts the non-exterior surface of the product 1. The placement of the meshing teeth 41 will result in a recessed surface on the product 1 after injection molding. Therefore, disposing the meshing teeth 4 on the wall of the mold cavity 15 that contacts the non-exterior surface of the product 1 ensures that the recessed surface is formed on the non-exterior surface of the product 1, thereby preventing the recessed surface from affecting the appearance of the product 1.

[0060] In this embodiment, a plurality of meshing teeth 4 are arranged in a spaced-apart manner in the mold cavity 15, and at least two are arranged on the peripheral side of the gate 3 of the mold. Because the scouring force of the injected resin on the diaphragm is the greatest at the gate 3 of the mold, more meshing teeth 4 are arranged to increase the fixing effect on the diaphragm 2 and prevent the diaphragm 2 from wrinkling or deformation due to resin scouring.

[0061] When the mold is closed, before the mold is closed, the protruding tooth-like structure 401 will contact the surface of the diaphragm 2. Continuing the mold closing stroke will allow the protruding tooth-like structure 401 to continue to move forward and press the diaphragm 2, which will produce a certain deformation on the diaphragm 2, so it is called an interference fit.

[0062] A full circle of exhaust grooves 11, a vacuum pipe 13 and a local exhaust groove 14 are provided in the movable side exhaust insert 8; the cavity 15, the local exhaust groove 14, the full circle of exhaust grooves 11 and the vacuum pipe 13 are connected in sequence.

[0063] Example 2:

[0064] Those skilled in the art may understand this embodiment as a more specific description of Embodiment 1.

[0065] The injection molding process for in-mold lamination of external lenses is as follows: a) Place the conformable film into the mold cavity; b) Close the mold; c) Injection molding; d) Open the mold to remove the product; e) Next cycle. During stage a, positioning the film is a challenge, while during stage c, securing the film is another.

[0066] In stage a, the diaphragm itself conforms to the shape, and any local deviation from its position can result in an overall erroneous final product. There's a gap between the plastic diaphragm and the steel mold cavity. When placed upright on the mold, it tends to fall due to gravity, and vibration occurs during mold closing. These factors can all cause the diaphragm to deviate from its preset position. Therefore, this embodiment utilizes a position-limiting structure and vacuum extraction to prevent the diaphragm from deviating from its preset position.

[0067] In stage c, the main difficulty lies in the erosion of the diaphragm by the high-temperature and high-speed resin during the injection molding process. This erosion may cause problems such as wrinkling and deformation of the diaphragm. Therefore, this embodiment uses the protruding tooth-like structure 401 to fix the diaphragm to prevent wrinkling or deformation.

[0068] This embodiment provides a mold for inner injection molding of an outer lens film, which addresses these two challenges by setting corresponding structures in the mold.

[0069] Several limiting bosses 5 are provided on one side of the gate 3 of the product 1 (also the side not visible from the outside), corresponding to several limiting holes 201 on the diaphragm 2. The limiting bosses 5 are conical bosses with a draft angle of 10 degrees. The limiting holes 201 on the diaphragm 2 are 0.1 to 0.5 mm larger than the conical sidewalls.

[0070] For injection molding, the place with the highest fluid shear rate appears near the gate 3. This position is also the place with the greatest impact on the diaphragm 2. In order to ensure that the diaphragm 2 will not be dislocated under high shear, meshing teeth 4 are set on the opposite side of the cavity wall where the diaphragm 2 is located. In this embodiment, two rows of meshing teeth 4 are directly set on both sides of the gate 3, and a single row of meshing teeth 4 is composed of two protruding tooth structures 401. In order not to affect the flow of the fluid, the tip of the protruding tooth structure 401 should not be set too large. In this embodiment, the tip of the protruding tooth structure 401 is set to R0.5~R1mm, and the tooth tip of the protruding tooth structure 401 is an interference fit with the diaphragm 2. The diaphragm 2 at the meshing pressure point has a thickness of 0.2~0.4mm. By fully chamfering the head of the protruding tooth structure 401 to be close to a hemispherical shape, the protruding tooth structure 401 will not penetrate the diaphragm 2 and cause problems. By controlling the aspect ratio of the tooth to be >1 / 5, the strength of the tooth feature is ensured to prevent the occurrence of thin steel.

[0071] The outer lens of the headlight is usually a 3D curved surface, most of which is also the appearance surface. There is no way to set the corresponding structure on this part of the curved surface because it will affect the visual characteristics. However, this part has a large area. In order to make this part fit well with the cavity, this embodiment uses the vacuum adsorption method. Figure 8As shown, a movable side vacuum insert 8 is removed from the movable side main insert 7. A full circle of exhaust grooves 11 are provided on the movable side vacuum insert 8, approximately 5 to 50 mm from the product surface. A vacuum channel 13 is provided within the movable side vacuum insert 8. To ensure vacuum, a sealing ring groove 12 is provided around the insert fixing bolts 16 at the bottom of the insert. A rubber ring is embedded in the sealing ring groove 12 to prevent air from entering the vacuum channel through the bolt holes and affecting suction.

[0072] The utility model solves the problem of easy misalignment of diaphragm placement by arranging a boss on the non-appearance surface of the periphery of the cavity of the mold, realizes fast and reliable diaphragm placement, and achieves the effect of reducing operation time and improving yield rate.

[0073] In the description of this application, it should be understood that the terms "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this application.

[0074] The above describes specific embodiments of the present invention. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art may make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. The embodiments of this application and the features in the embodiments may be combined with each other in any manner unless there is a conflict.

Claims

1. A mold for inner injection molding of an outer lens film, characterized in that: include: A fixed side main insert (6) and a movable side main insert (7); A cavity (15) is formed between the fixed-side main insert (6) and the movable-side main insert (7), and a diaphragm (2) is arranged in the cavity (15); A limiting boss (5) is arranged in the mold cavity (15), a limiting hole (201) is arranged on the diaphragm (2), the limiting boss (5) is located in the limiting hole (201), and the limiting boss (5) and the limiting hole (201) are used to limit and fix the diaphragm (2).

2. The mold for inner injection molding of outer lens film according to claim 1, characterized in that: The cavity (15) is provided with meshing teeth (4), the meshing teeth (4) abut against the diaphragm (2), and the meshing teeth (4) are used to limit and fix the diaphragm (2).

3. The mold for inner injection molding of outer lens film according to claim 2, characterized in that: The meshing teeth (4) are provided in plurality, and the plurality of meshing teeth (4) are distributed and arranged in the mold cavity (15); And / or, one or more meshing teeth (4) are distributed around the gate (3) of the mold.

4. The mold for inner injection molding of outer lens film according to claim 2, characterized in that: The meshing teeth (4) include one or more connected protruding tooth structures (401).

5. The mold for inner injection molding of outer lens film according to claim 4, characterized in that: The tooth tip of the protruding tooth structure (401) is arranged in an arc shape.

6. The mold for inner injection molding of outer lens film according to claim 4, characterized in that: The tooth tip of the protruding tooth structure (401) is arranged in an interference fit with the diaphragm (2).

7. The mold for inner injection molding of outer lens film according to claim 1, characterized in that: The fixed side main insert (6) is provided with a fixed side exhaust insert (9) and a hot runner insert (10); The fixed side exhaust insert (9) and the hot runner insert (10) are both arranged in communication with the mold cavity (15).

8. The mold for inner injection molding of outer lens film according to claim 1, characterized in that: A movable side air extraction insert (8) is arranged inside the movable side main insert (7); The movable side air extraction insert (8) is connected to the mold cavity (15).

9. The mold for inner injection molding of outer lens film according to claim 8, characterized in that: The movable side exhaust insert (8) is provided with an exhaust groove (11) in a full circle, a vacuum pipe (13) and a local exhaust groove (14); The mold cavity (15), the local exhaust groove (14), the full circle exhaust groove (11) and the vacuum extraction pipeline (13) are sequentially connected and arranged.

10. The mold for inner injection molding of outer lens film according to claim 8, characterized in that: The movable side main insert (7) and the movable side exhaust insert (8) are connected and fixed by insert fixing bolts (16); The movable side air extraction insert (8) is provided with a sealing ring groove (12), and a rubber ring is provided in the sealing ring groove (12); The rubber ring is located between the movable side main insert (7) and the movable side air extraction insert (8), and the rubber ring is arranged around the insert fixing bolt (16).

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