Method for manufacturing gasket members and gasket assembly

Abstract

The present invention provides a method for manufacturing a gasket member and a gasket assembly that can suppress the risk of air bubbles forming within the gasket member. [Solution] The method for manufacturing a gasket member according to the present disclosure uses a mold. In the method for manufacturing a gasket member, the cavity 1a of the mold 1 includes a product cavity 1d having a shape that can transfer the shape of the gasket member R1d, a vent 1e for discharging gas from inside the product cavity 1d, and a connecting portion 1f. When the mold 1 and the plate-shaped base material 2 are clamped together, the connecting portion 1f extends in a direction intersecting the contact surface 1g where the mold 1 and the base material 2 come into contact, connecting the product cavity 1d and the vent 1e. The gasket member R1d is formed by clamping the mold 1 and the base material 2 together and injecting resin into the cavity 1a of the mold 1.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a gasket member and a gasket assembly.

Background Art

[0002] In the method for manufacturing a gasket member disclosed in Patent Document 1, a plate-shaped base material is clamped between a first split mold and a second split mold, and a rubber-like elastic material is injected and filled into a gasket cavity defined between the base material and the first split mold. Thereby, a gasket member in which a gasket is fixed to the surface of the base material is manufactured. An air vent is provided in the first split mold. When injecting and filling the rubber-like elastic material into the cavity, the air in the cavity is discharged through the air vent. The air vent has an exhaust groove portion and an exhaust hole portion. The exhaust groove portion is provided so as to extend from the cavity to the inner peripheral side or the outer peripheral side on the abutting surface between the base material and the first split mold and partially open in the circumferential direction of the cavity. The exhaust hole portion extends from the exhaust groove portion in the mold clamping direction of the first split mold and the second split mold.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The inventors of the present application have discovered the following problems. In such a method for manufacturing a gasket member, various materials including a rubber-like elastic material can be used. As one of such various materials, there is a UV curable resin material. In such a method for manufacturing a gasket member, when injecting and filling a material into the cavity, the air in the cavity may not be sufficiently discharged. Therefore, there is a risk of generating air bubbles in the gasket member.

[0005] This disclosure has been made in view of the above-mentioned problems, and provides a method for manufacturing a gasket member and a gasket assembly that can suppress the risk of air bubbles forming inside the gasket member. [Means for solving the problem]

[0006] The method for manufacturing a gasket member according to this disclosure is: A method for manufacturing a gasket member using a mold, The cavity of the mold is A product cavity having a shape that can transfer the shape of the gasket member, A vent for discharging gas from the product cavity, It includes a connecting part, The aforementioned connecting portion extends in a direction intersecting the contact surface where the mold and the plate-shaped base material come into contact when the mold and the plate-shaped base material are clamped together, connecting the product cavity and the vent. The gasket member is formed by clamping the mold and the substrate together and injecting resin into the cavity of the mold.

[0007] The gasket assembly relating to this disclosure is A gasket member made of resin is fixed to the aforementioned base material, A gasket assembly comprising a residual resin portion integrally formed with the gasket member using a mold, The residual resin portion extends from the gasket member in a direction away from the base material, The residual resin portion has traces of where the vent resin portion, onto which the shape of the molded vent was transferred, was removed. [Effects of the Invention]

[0008] According to this disclosure, the risk of air bubbles forming within the gasket member can be suppressed. [Brief explanation of the drawing]

[0009] [Figure 1]This is a plan view of the molding die according to Embodiment 1. [Figure 2] These are cross-sectional views and enlarged cross-sectional views of the cutting line II-II of the mold according to Embodiment 1. [Figure 3] This is a cross-sectional view of the molding die according to Embodiment 1 at the cutting line III-III. [Figure 4] This is a schematic diagram showing one step in the manufacturing method of a gasket member according to Embodiment 1. [Figure 5] This is a schematic diagram showing another step in the manufacturing method of the gasket member according to Embodiment 1. [Modes for carrying out the invention]

[0010] Specific embodiments of the present invention will be described in detail below with reference to the drawings. However, the present invention is not limited to the following embodiments. Also, for clarity of explanation, the following description and drawings have been simplified as appropriate.

[0011] <Embodiment> A method for manufacturing a gasket member according to an embodiment will be described with reference to Figures 1 to 5. Figure 1 is a plan view of the mold according to Embodiment 1. Figure 2 is a cross-sectional view and an enlarged cross-sectional view of the mold shown in Figure 1 along the cutting line II-II. Figure 3 is a cross-sectional view of the mold shown in Figure 1 along the cutting line III-III. Figure 4 is a schematic diagram showing one step of the method for manufacturing a gasket member according to Embodiment 1. Figure 5 is a schematic diagram showing another step of the method for manufacturing a gasket member according to Embodiment 1.

[0012] It should be noted that the right-handed XYZ coordinate system shown in Figure 1 and other drawings is merely for convenience in explaining the positional relationships of the components. Typically, the positive Z-axis direction is vertically upward, and the XY plane is the horizontal plane, and this is consistent across drawings.

[0013] In the method for manufacturing a gasket member according to the embodiment, for example, the molding apparatus 10 shown in Figures 1 to 3 can be used.

[0014] The molding device 10 includes a mold 1. The molding device 10 may include a device capable of clamping the mold 1 and the base material 2. The mold 1 and the base material 2 may be held in a clampable manner by an injection molding device (not shown). In addition to the injection molding device, a mold made of a metal material may also be used to clamp the mold 1 and the base material 2. The molding device 10 may include an ultraviolet light irradiation device.

[0015] The base material 2 is preferably a plate-shaped member to which a gasket member can be fixed. The base material 2 is preferably made of, for example, a metal material. Such a metal material is, for example, an aluminum alloy or the like. The base material 2 is preferably a member that can be used as a separator. The separator can be used as a member of a fuel cell.

[0016] The mold 1 has a cavity 1a. The cavity 1a is preferably formed by cutting. The cavity 1a includes an injection port 1b, a gate 1c, a product cavity 1d, a vent 1e, and a connection portion 1f. The injection port 1b, the gate 1c, the product cavity 1d, the vent 1e, and the connection portion 1f are continuous spaces. The mold 1 is preferably, for example, a plate-like body. The mold 1 has a contact surface 1g that contacts the base material 2 when the mold 1 and the base material 2 are clamped. The mold 1 is preferably made of a material that transmits ultraviolet light. Such materials are, for example, acrylic resin, polycarbonate, polyethylene terephthalate, polyvinyl chloride, polystyrene, glass materials, etc.

[0017] The injection port 1b opens on the upper surface 1h. The upper surface 1h faces in the opposite direction (here, the positive Z-axis direction) to the contact surface 1g. The injection port 1b is an opening into which a liquefied material can be injected. This material may be any material that can form a gasket member, for example, rubber, resin elastomer, UV (ultraviolet) curable resin, etc. The UV curable resin cures when irradiated with ultraviolet light. The UV curable resin is, for example, acrylic resin, epoxy resin, etc. The material that can form the gasket member and the material that forms the mold 1 are preferably different.

[0018] Gate 1c connects the inlet 1b and the product cavity 1d.

[0019] The product cavity 1d has a shape that can transfer the shape of the gasket member described above. The product cavity 1d may extend in an annular shape. An example of the product cavity 1d according to this embodiment shown in Figure 1 extends in a roughly square shape with rounded corners.

[0020] The vent 1e opens on the upper surface 1h. The vent 1e is positioned on the upper surface 1h at a predetermined distance from the inlet 1b. The vent 1e is preferably positioned at or near the point where the material injected into the inlet 1b merges within the product cavity 1d. The vent 1e allows the gas inside the product cavity 1d to pass through the connection part 1f and be discharged.

[0021] The connecting portion 1f extends from the product cavity 1d in a direction intersecting the contact surface 1g to the vent 1e. The direction intersecting the contact surface 1g may be, for example, the clamping direction (in this case, the Z-axis direction) that clamps the mold 1 and the base material 2 together. The connecting portion 1f connects the product cavity 1d and the vent 1e.

[0022] At the contact surface 1g, the connecting portion 1f is positioned on the outer or inner side of the product cavity 1d. Specifically, as shown in Figure 1, at the contact surface 1g, the connecting portion 1f is preferably positioned inside the outer circumference 1da of the product cavity 1d. Alternatively, at the contact surface 1g, the connecting portion 1f is preferably positioned inside the inner circumference 1db of the product cavity 1d. Furthermore, at the contact surface 1g, the connecting portion 1f is preferably contained within the projection of the gasket projection area, i.e., the projection of the product cavity 1d on the contact surface 1g. The ratio of the width Wf of the connecting portion 1f to the width Wd of the product cavity 1d shown in Figure 2 is preferably 0.5 or less. Also, the ratio of the length Tf of the connecting portion 1f in the clamping direction to the length Td of the product cavity 1d in the clamping direction is preferably 0.8 or more and less than 1.0. Finally, the draft angle α of the connecting portion 1f is preferably 5° or more.

[0023] Next, an example of a method for manufacturing a gasket member according to this embodiment will be described. In this example of a method for manufacturing a gasket member according to this embodiment, the material is a UV-curing resin, and the mold 1 is made of a material that transmits ultraviolet light.

[0024] As shown in Figure 4, the mold 1 and the substrate 2 are clamped together, and the liquefied UV-curing resin is injected into the cavity 1a of the mold 1 (step ST1).

[0025] The injected UV-curing resin fills the inlet 1b, gate 1c, product cavity 1d, connector 1f, and vent 1e in that order. Upon entering the product cavity 1d from gate 1c, the injected UV-curing resin branches. These branched UV-curing resins continue through the product cavity 1d and merge near connector 1f. This can cause air within the product cavity 1d to be drawn in, resulting in the formation of bubbles within the UV-curing resin. Furthermore, this merged UV-curing resin flows into connector 1f and vent 1e. The bubbles may move into the UV-curing resin within connector 1f and then further into the UV-curing resin within vent 1e. In other words, in many cases, bubbles formed in the UV-curing resin within the product cavity 1d move into the UV-curing resin within connector 1f and vent 1e.

[0026] Next, ultraviolet light is irradiated onto the mold 1 (step ST2). Specifically, an object that blocks ultraviolet light should be placed away from the mold 1 as appropriate, and ultraviolet light should be irradiated onto the mold 1 using an ultraviolet light irradiation device. The ultraviolet light passes through the mold 1 and reaches the UV-curable resin. The UV-curable resin hardens and solidifies upon irradiation with ultraviolet light. Once the UV-curable resin solidifies, a resin molded body R1a is formed.

[0027] The resin molded body R1a includes an injection port resin part R1b, a gate resin part R1c, a gasket member R1d, a vent resin part R1e, and a residual resin part R1f. The injection port resin part R1b is placed inside the injection port 1b. The gate resin part R1c is placed inside the gate 1c. The gasket member R1d is placed inside the product cavity 1d. The vent resin part R1e is placed inside the vent 1e. The shape of the vent 1e is transferred to the vent resin part R1e. The residual resin part R1f is placed inside the connection part 1f. The gasket member R1d and the vent resin part R1e are connected via the residual resin part R1f.

[0028] Finally, as shown in Figure 5, the mold 1 is removed from the base material 2 (step ST3). Specifically, the mold 1 is removed from the base material 2 in such a way that the vent resin part R1e is separated from the residual resin part R1f, while the residual resin part R1f remains connected to the gasket member R1d. A trace R1g is left on the residual resin part R1f where the vent resin part R1e was separated. The gasket member R1d is fixed to the base material 2. The gasket assembly R10 is formed by the fixing of the gasket member R1d to the base material 2. The vent resin part R1e remains in the vent 1e. Alternatively, the inlet resin part R1b may be separated from the gate resin part R1c, while the gate resin part R1c remains connected to the gasket member R1d. The inlet resin part R1b remains in the inlet 1b.

[0029] From the above, the gasket member R1d can be manufactured. In step ST1, in most cases, air bubbles generated in the UV-curing resin in the product cavity 1d move into the UV-curing resin in the connection part 1f and the vent 1e. In step ST2, when the UV-curing resin solidifies, the air bubbles remain in the residual resin part R1f and the vent resin part R1e. In step ST3, the vent resin part R1e is separated from the residual resin part R1f. Therefore, the risk of air bubbles forming in the gasket member R1d can be suppressed.

[0030] Furthermore, in the example of the manufacturing method described above, the connecting portion 1f is positioned on the outside or inside of the product cavity 1d at the contact surface 1g. Also, the ratio of the width Wf of the connecting portion 1f to the width Wd of the product cavity 1d is 0.5 or less. As a result, since the connecting portion 1f is close to the product cavity 1d, it is possible to move air bubbles from the UV-curing resin in the product cavity 1d to the UV-curing resin in the connecting portion 1f. Therefore, it is possible to further suppress the generation of air bubbles within the gasket member R1d.

[0031] Furthermore, in the example of the manufacturing method described above, the ratio of the length Tf of the connecting portion 1f in the clamping direction to the length Td of the product cavity 1d in the clamping direction is 0.8 or more and less than 1.0. Bubbles may rise within the UV-curing resin and concentrate on the upper surface 1h side of the product cavity 1d. Therefore, it is possible to move bubbles from the UV-curing resin in the product cavity 1d to the UV-curing resin in the connecting portion 1f. Consequently, it is possible to further suppress the generation of bubbles within the gasket member R1d.

[0032] The gasket assembly R10 comprises a base material 2, a gasket member R1d, and a residual resin portion R1f. The gasket assembly R10 may further include a gate resin portion R1c. As described above, the gasket member R1d and the residual resin portion R1f are integrally formed using a mold 1. The residual resin portion R1f extends from the gasket member R1d in a direction away from the base material 2. Specifically, the residual resin portion R1f extends in a direction away from the base material 2 along a direction intersecting the main surface 2a of the base material 2. One example of such a direction is perpendicular to the main surface 2a of the base material 2. The residual resin portion R1f has a trace R1g where the vent resin portion R1e was removed. On the main surface 2a of the base material 2, the residual resin portion R1f may be positioned outside or inside the gasket member R1d. Furthermore, the ratio of the width of the residual resin portion R1f to the width of the gasket member R1d may be 0.5 or less. The ratio of the height of the residual resin portion R1f to the height of the gasket member R1d should be between 0.8 and less than 1.0. The ratio of the width of the residual resin portion R1f to the width of the gasket member R1d should be 0.5 or less.

[0033] Furthermore, gasket member R1d can be used as gasket assembly R10 even if at least one of the gate resin part R1c and the residual resin part R1f remains connected. Even if the gate resin part R1c and the residual resin part R1f are connected to gasket member R1d, the gasket function of gasket assembly R10 is not significantly affected, and the necessary gasket function can be ensured.

[0034] It should be noted that the present invention is not limited to the embodiments described above, and can be modified as appropriate without departing from the spirit of the invention. Furthermore, the present invention may be implemented by appropriately combining the above embodiments or examples thereof. The cavity 1a of the mold 1 according to this embodiment is equipped with a vent 1e, but may further be equipped with another vent in addition to vent 1e. The other vent may be provided, for example, at the corners of the product cavity 1d which extends in a substantially rectangular shape. The other vent may be at least one of two corners of the product cavity 1d that are closer to vent 1e than to the injection port 1b. [Explanation of Symbols]

[0035] 10 Molding equipment 1 mold 1a Cavity 1b Inlet 1c gate 1d Product Cavity 1da outer perimeter 1 dB inner circumference 1e Vent 1f Connection 1g contact surface 1h top 2 Base material 2a Main surface R1a Resin Molded Body R1b Inlet resin part R1c Gate Resin Part R1d Gasket component R1e Vented resin part R1f Residual resin part R1g trace Td, Tf Length Wd, Wf width α Draft angle

Claims

1. A method for manufacturing a gasket member using a mold, The cavity of the mold is A product cavity having a shape that can transfer the shape of the gasket member, A vent for discharging gas from the product cavity, It includes a connecting part, The aforementioned connecting portion extends in a direction intersecting the contact surface where the mold and the plate-shaped base material come into contact when the mold and the plate-shaped base material are clamped together, connecting the product cavity and the vent. A gasket member is formed by clamping the mold and the substrate together and injecting resin into the cavity of the mold. A method for manufacturing gasket components.

2. The gasket member is formed such that the gasket member and the vent resin portion are connected via the residual resin portion, while the vent resin portion is formed within the vent, and the gasket member is formed such that the residual resin portion and the vent resin portion are connected via the residual resin portion. The mold is removed from the base material such that the vent resin portion is separated from the residual resin portion while the residual resin portion remains connected to the gasket member. A method for manufacturing a gasket member according to claim 1.

3. When the mold and the substrate are clamped together, the connecting portion is positioned on the outer or inner circumference side of the product cavity at the contact surface where the mold and the substrate come into contact. A method for manufacturing a gasket member according to claim 1 or 2.

4. The ratio of the length of the connecting portion in the clamping direction to the length of the product cavity in the clamping direction is 0.8 or more and less than 1.

0. A method for manufacturing a gasket member according to claim 1 or 2.

5. The ratio of the width of the connecting portion to the width of the product cavity is 0.5 or less. A method for manufacturing a gasket member according to claim 1 or 2.

6. Substrate and A gasket member made of resin is fixed to the aforementioned base material, A gasket assembly comprising a residual resin portion integrally formed with the gasket member using a mold, The residual resin portion extends from the gasket member in a direction away from the base material, The residual resin portion has traces of where the vent resin portion, on which the shape of the mold vent was transferred, was removed. Gasket assembly.

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