Manufacturing method of molded products

Abstract

To reduce work hours of a process for assembling a seal member to a housing.SOLUTION: A face seal with a resin plate includes a resin plate and a seal member 50. The face seal with the resin plate has an adhesive layer formed by curing surfaces of the resin plate and the seal member 50, and the resin plate and the seal member 50 are integrated by the adhesive layer. In the face seal with the resin plate, the resin plate 65 is peeled from the seal member 50 to expose the adhesive layer 53 and the exposed adhesive layer 53 is pressed against a housing body 17 to assemble the seal member 50 to the housing body 17.SELECTED DRAWING: Figure 9

Description

[Technical Field]

[0001] The present invention relates to a molded article, a housing, a method for manufacturing a molded article, and a method for manufacturing a housing. [Background technology]

[0002] For example, a terminal block that is attached to a body panel of a vehicle or a case of an equipment has a resin housing that holds terminals. One such type of terminal block has an annular seal member provided on the mounting surface of the terminal block housing to the panel, which is pressed against the mounting surface of the panel to seal the gap with the panel (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2010-211933 Summary of the Invention [Problem to be solved by the invention]

[0004] In the terminal block described in Patent Document 1, the housing is fastened to the panel with bolts, which presses the seal member evenly against the surface of the panel and ensures good sealing. This terminal block has a structure in which pins provided on the housing are inserted into pin holes in the seal member to hold the seal member in place. The terminal block also has a structure in which a columnar portion with an enlarged end is provided on the seal member and is fitted into a through-hole on the housing to hold the seal member in place. These holding structures may need to be provided in multiple locations depending on the size of the seal member, and the seal member must be fitted in each location, resulting in increased processing time.

[0005] The present invention has been made in view of the above-mentioned circumstances, and its object is to reduce the number of processing steps required when assembling a seal member to a housing. Growth How to manufacture shaped products law The purpose is to provide [Means for solving the problem]

[0008] before In order to achieve the above-mentioned object, the method for producing a molded article according to the present invention is characterized as follows. a material introduction step of introducing a material constituting the sealing member into the mold having the plate disposed therein; a molding step of pressurizing the interior to vulcanize the surfaces of the plate and the sealing member to produce a molded product having an adhesive layer formed thereon; and a removal step of removing the molded product from the mold. Manufacturing method of molded products. [Effects of the Invention]

[0010] The present invention Growth How to manufacture shaped products law This provides the effect of reducing the number of processing steps required to assemble the seal member to the housing.

[0011] The present invention has been briefly described above. The details of the present invention will become clearer by reading the following detailed description of the invention (hereinafter referred to as "embodiments") with reference to the accompanying drawings. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 is a perspective view of a terminal block and case equipped with a housing according to one embodiment of the present invention. [Figure 2] FIG. 2 is a vertical cross-sectional view of the terminal block attached to the case. [Figure 3] FIG. 3 is a perspective view of the housing as seen from the assembly portion side. [Figure 4] FIG. 4 is a diagram for explaining a method for manufacturing a resin plate-mounted face seal according to one embodiment of the present invention, showing a resin plate arrangement step. [Figure 5]FIG. 5 is a diagram for explaining a method for manufacturing a resin plate-mounted face seal according to one embodiment of the present invention, showing a material introduction step. [Figure 6] FIG. 6 is a diagram for explaining a method for manufacturing a resin plate-mounted face seal according to one embodiment of the present invention, showing a pressurizing step. [Figure 7] FIG. 7 is a diagram for explaining a method for manufacturing a resin plate-mounted face seal according to one embodiment of the present invention, showing a removal step. [Figure 8] FIG. 8 is a diagram illustrating a method for manufacturing a housing according to an embodiment of the present invention, showing a peeling step. [Figure 9] FIG. 9 is a diagram illustrating a method for manufacturing a housing according to an embodiment of the present invention, showing an assembly step. DETAILED DESCRIPTION OF THE INVENTION

[0013] Specific embodiments of the present invention will be described below with reference to the accompanying drawings.

[0014] Fig. 1 is a perspective view of a terminal block 11 equipped with a housing 13 according to one embodiment of the present invention and a case 1. Fig. 2 is a vertical cross-sectional view of the terminal block 11 attached to the case 1. As shown in Figures 1 and 2, the housing 13 according to this embodiment is made up of a housing main body 17 and a holder 19. The holder 19, which has a plurality of terminals 15, is attached to the upper part of the housing main body 17. The housing 13 and these terminals 15 form a terminal block 11. The terminal block 11 is attached to the case 1 of a drive motor mounted in, for example, a hybrid vehicle or an electric vehicle. The housing 13 is not limited to the terminal block 11, and may also be the housing of various devices such as a connector or an electric junction box.

[0015] The housing 13 is made up of a housing main body 17 and a holder 19, which are molded from insulating resin, with the upper side of the holder 19 being a fastening portion 21 and the lower side of the housing main body 17 being an assembly portion 23. The housing 13 has a flange portion 25 extending outward between the fastening portion 21 and the assembly portion 23, and this flange portion 25 has a plurality of bolt insertion holes 27 formed therein.

[0016] The terminal block 11 is fitted with an assembly portion 23 of a housing 13 into a mounting hole 2 formed in a case 1 of a drive motor or the like. A mounting surface 3 consisting of a smooth surface is formed on the edge of the mounting hole 2 in the case 1. With the assembly portion 23 of the housing 13 fitted into the mounting hole 2, the terminal block 11 is assembled to the mounting surface 3 of the case 1 by passing a bolt 4 through a bolt insertion hole 27 in a flange portion 25 and screwing it into a screw hole 5 formed in the case 1.

[0017] The housing main body 17 of the housing 13 is provided with an annular seal member 50 on the side where it is attached to the case 1. When the housing 13 is attached to the case 1, this seal member 50 comes into close contact with the attachment surface 3 of the case 1. This creates a liquid-tight seal between the housing main body 17 and the attachment surface 3 of the case 1.

[0018] The housing body 17 of the housing 13 has a plurality of terminal insertion holes 30 that penetrate from the front to the back. An attachment recess 18 is provided above the terminal insertion holes 30, to which the holder 19 is attached. A seal member 31 having a seal hole 32 is attached between the housing body 17 and the holder 19.

[0019] A nut accommodating recess 41, which is a recess having a rectangular shape in a plan view, is provided on the mounting portion 23 side of the housing 13. The nut accommodating recess 41 has an open lateral side. A nut 42 having a rectangular shape in a plan view and a screw hole 42a extending from the lateral side is accommodated in the nut accommodating recess 41. A counterbore 43 is formed in the bottom 41a of the nut accommodating recess 41.

[0020] The terminals 15 attached to the holders 19 of the housing 13 are made of a conductive metal material such as copper or a copper alloy, and are in the form of plate-shaped bus bars. The terminals 15 have fastening holes 45 formed on one end and connection holes 46 formed on the other end.

[0021] The terminal 15 is attached to the housing 13 by inserting it into the terminal insertion hole 30 with the end where the connection hole 46 is formed facing the nut accommodating recess 41 where the nut 42 is accommodated. Then, the terminal 15 is positioned so that the connection hole 46 faces the nut 42 accommodated in the nut accommodating recess 41 and communicates with the screw hole 42a.

[0022] Furthermore, the terminal 15 inserted into the terminal insertion hole 30 is inserted into the seal hole 32 of the seal member 31. As a result, the inner peripheral surface of the seal hole 32 of the seal member 31 is tightly attached to the outer peripheral surface of the terminal 15, and the gap between the terminal 15 and the terminal insertion hole 30 is liquid-tightly sealed.

[0023] Wiring members such as terminal fittings and bus bars on the device side are connected to the terminals 15 of the terminal block 11 on the assembly portion 23 side of the housing 13. To connect the wiring members to the terminals 15, a bolt (not shown) is inserted into a hole (not shown) formed in the wiring member, the bolt is passed through a connection hole 46 of the terminal 15, and screwed into a threaded hole 42a of a nut 42 housed in the nut accommodating recess 41. In this manner, the wiring member is fastened and connected to the terminal 15 by the bolt and the nut 42. In this fastened state, the end of the bolt passes through a counterbore hole 43 formed in the bottom 41a of the nut accommodating recess 41 without interfering with the bottom 41a.

[0024] Furthermore, wiring materials such as terminal fittings and bus bars on the device to be connected are connected to the terminals 15 of the terminal block 11 on the fastening portion 21 side of the housing 13. To connect these wiring materials to the terminals 15, bolts (not shown) are inserted into holes (not shown) formed in the wiring materials, and the bolts are passed through fastening holes 45 of the terminals 15 and screwed into nuts (not shown). In this way, the wiring materials are fastened and connected to the terminals 15 by the bolts and nuts.

[0025] Next, the seal member 50 provided in the housing body 17 will be described in detail. FIG. 3 is a perspective view of the housing 13 as viewed from the mounting portion 23 side. As shown in FIG. 3, a seal mounting groove 28 is formed circumferentially on the side of the housing 13 where the housing main body 17 is mounted to the case 1. A seal member 50 is provided in this seal mounting groove 28. The seal member 50 is molded from an oil-resistant resin material, such as acrylic. As described below, the seal member 50 has an adhesive layer 53 formed by vulcanization on one side, and is adhered to the mounting surface 28a of the housing main body 17, which is the bottom surface of the seal mounting groove 28, by the adhesive layer 53 (see FIG. 9). The seal member 50 includes an annular seal portion 52 having a seal surface 51 on the side opposite the adhesive layer 53. The annular seal portion 52 has a thickness dimension greater than the depth dimension of the seal mounting groove 28. As a result, the seal surface 51 of the annular seal portion 52 protrudes from the seal mounting groove 28 along the entire circumference. The seal member 50 has a seal surface 51 of the annular seal portion 52 that is in close contact with the mounting surface 3, and the gap between the case 1 and the housing 13 is liquid-tightly sealed in the seal area where the seal surface 51 is in close contact.

[0026] By providing the seal mounting groove 28 in the housing body 17, after the terminal block 11 is attached to the case 1, the seal member 50 is covered by the outer portion of the seal mounting groove 28 in the housing body 17, protecting the seal member 50 from the water pressure of a high-pressure wash, dust, and the like. Furthermore, after the terminal block 11 is bolted to the case 1, the housing body 17 may bend due to the repulsive force of the seal member 50. However, by providing the seal mounting groove 28, the outer portion of the seal mounting groove 28 in the housing body 17 functions as a rib, thereby improving the housing strength. Note that because the seal member 50 can be directly attached and fixed to the housing body 17, the seal mounting groove 28 is not necessarily provided. By not providing the seal mounting groove 28, the configuration of the housing body 17 can be simplified.

[0027] 4 to 7, a method for manufacturing the seal member 50 will be described. The seal member 50 is molded as a resin plate-attached surface seal 70 integrated with a resin plate 65, and then attached to the housing main body 17 with the resin plate 65 removed during the assembly process of the housing 13. The resin plate 65 is an example of a plate, and the resin plate-attached surface seal 70 is an example of a molded product.

[0028] 4 to 6 show schematic cross sections of a lower mold 61, a middle mold 62, and an upper mold 63, which are molds for molding the resin plate-attached surface seal 70. In this embodiment, the lower mold 61, the middle mold 62, and the upper mold 63 are maintained in a state where they are heated to a predetermined temperature. 4, a resin plate 65 made of a nylon resin such as nylon 6 or nylon 66 is placed in advance in the cavity for the resin plate of the lower mold 61. On the upper surface of the lower mold 61 with the resin plate 65 placed inside, a middle mold 62 provided with a cavity for a sealing member is placed.

[0029] As shown in FIG. 5, a face seal material 66, such as acrylic resin, that will form the seal member 50 is poured into the seal member cavity of the middle die 62. Next, as shown in FIG. 6, an upper die 63 is placed on top of the middle die 62, and pressure is applied to the cavity containing the resin plate 65 and face seal material 66. After the pressurization, the cavity is left for a certain period of time, during which the surfaces of the resin plate 65 and the face seal material 66 are vulcanized to form an adhesive layer. This adhesive layer then forms a resin-plate-attached face seal 70, in which the resin plate 65 and the seal member 50 are integrated together. Then, as shown in FIG. 7, the resin-plate-attached face seal 70 is removed from the upper die 63, middle die 62, and lower die 61. The resin-plate-attached face seal 70 manufactured as described above is transported to the housing 13 assembly process.

[0030] Next, a method for manufacturing the housing 13 will be described with reference to Figures 8 and 9. As shown in Figure 8, in the resin plate-attached surface seal 70, the resin plate 65 is peeled off from the seal member 50 to expose the adhesive layer 53. The surface of the seal member 50 opposite the adhesive layer 53 forms the seal surface 51. Next, as shown in Figure 9, the exposed adhesive layer 53 is placed opposite the housing main body 17, and the seal member 50 is pressed against the mounting surface 28a of the seal mounting groove 28 to assemble the seal member 50 to the housing main body 17, thereby manufacturing the housing 13 (see Figure 3).

[0031] In this embodiment, the mold is heated to a predetermined temperature in advance, but the heating step is not essential, and the interface between the seal member 50 and the resin plate 65 may be vulcanized and integrated by the temperature rise caused by pressurization. Alternatively, the mold may be heated after the resin plate 65 and the face seal material 66 are placed in the mold.

[0032] The surface seal material 66 is an acrylic resin with additives pre-mixed therein, and the adhesive strength of the adhesive layer 53 can be adjusted by adjusting the amount of additive. That is, by adjusting the additive, the state of the adhesive layer 53 can be controlled, and the adhesive strength can be adjusted and the sealing member can be re-attached to a range that does not affect the sealing performance. The adhesive strength of the adhesive layer 53 can also be controlled by adjusting the additives contained in the material of the resin plate 65.

[0033] For example, if the resin plate 65 is made of nylon 66, the housing 13 is manufactured and then placed in an oven for secondary vulcanization, whereas if the resin plate 65 is made of nylon 6, the resin plate-mounted face seal 70 can be placed in an oven for secondary vulcanization. Therefore, in this case, many resin plate-mounted face seals 70 can be secondary vulcanized at once, reducing processing costs.

[0034] According to the resin plate-mounted surface seal 70 of this embodiment, the seal member 50 has adhesiveness at the interface with the resin plate 65, so that the seal member 50 can be directly attached to the housing main body 17 by using this adhesive force after the resin plate 65 has been peeled off. This eliminates the need to provide the housing 13 with a structure for holding the seal member 50 to the housing 13, allowing the housing 13 to be made more compact. Furthermore, because the seal member 50 is held to the housing main body 17 by attaching it to a predetermined position on the housing main body 17, the number of processing steps can be reduced compared to, for example, a case in which a pin provided on the housing is passed through a pin hole in the seal member to hold the seal.

[0035] Furthermore, by pressing the adhesive surface of the seal member 50 against the housing and holding it in place by the adhesive force, the seal member 50 can be attached even to a curved housing, allowing for greater freedom in the design of the housing.

[0036] Furthermore, when transporting adhesive sealing member 50, there is a concern that dust and other particles may adhere to the adhesive surface. However, by transporting sealing member 50 with resin plate 65 attached, i.e., resin plate-attached surface seal 70, adhesive layer 53 is covered by resin plate 65 and is not exposed, preventing dust and other particles from adhering to the adhesive surface.

[0037] Furthermore, by transporting the seal member 50 with the resin plate 65 attached, the seal member 50 is fixed to the resin plate 65 and the shape of the seal member 50 is maintained, eliminating the need to straighten the seal member 50 if it becomes deformed during transport. This makes it easier to assemble the seal member 50 to the housing main body 17 and facilitates automation of this assembly process.

[0038] The present invention is not limited to the above-described embodiments, and modifications, improvements, etc. are possible as appropriate. Furthermore, the materials, shapes, dimensions, numerical values, forms, numbers, locations, etc. of the components in the above-described embodiments are arbitrary and not limited as long as they achieve the present invention. For example, the number of terminals is not limited to those shown in the drawings, and may be, for example, six.

[0039] Here, the features of the embodiments of the molded article, housing, molded article manufacturing method, and housing manufacturing method according to the present invention described above will be briefly summarized and listed below in [1] to [8].

[0040] [1] Plate (resin plate 65) and a seal member (50), An adhesive layer is formed by vulcanizing the surfaces of the plate and the sealing member, and the plate and the sealing member are integrated by the adhesive layer. Molded product (resin plate-attached surface seal 70).

[0041] According to the molded product having the configuration [1] above, the sealing member has adhesiveness at the interface with the plate, so that the sealing member can be directly attached to, for example, a housing by using this adhesive force after the plate has been peeled off. This eliminates the need to provide a structure on the housing to hold the sealing member in place, allowing the housing to be made more compact. Furthermore, because the sealing member is held in place on the housing by attaching it to a predetermined position on the housing, the number of processing steps can be reduced compared to, for example, a case in which a pin provided on the housing is passed through a pin hole in the sealing member to hold the seal.

[0042] [2] At least one of the material constituting the plate and the material constituting the sealing member contains an additive for adjusting the adhesion degree of the adhesive layer. The molded product described in [1] above.

[0043] According to the molded product having the above-mentioned configuration [2], the condition of the interface with the peeled resin plate can be controlled by adjusting the additives, and the degree of adhesion can be adjusted and the sealing material can be reattached to a range that does not affect the sealing properties.

[0044] [3] A seal member (50) having an adhesive layer (53) formed by vulcanization; a housing body (17); The sealing member is adhered to the housing main body by the adhesive layer. Housing (13).

[0045] According to the housing of the configuration [3] above, the resin plate is peeled off to expose the adhesive layer of the sealing member, which is then attached to the housing, and the sealing member is assembled to the housing, and the housing is then assembled to the mounting portion. This assembly creates a seal between the housing and the mounting portion by the sealing surface, which is the surface opposite the adhesive layer. In this way, the sealing member can be easily assembled to the housing.

[0046] [4] A material introduction step (see FIG. 5 ) of introducing a material (face seal material 66) constituting the seal member (50) into a mold (lower mold 61, middle mold 62, upper mold 63) in which a plate (resin plate 65) is arranged; a molding process (see FIG. 6 ) in which the inside of the molded product (resin plate-mounted face seal 70) is produced by pressurizing the interior of the molded product and vulcanizing the surfaces of the plate and the seal member to form an adhesive layer; and a removal step (see FIG. 7) of removing the molded product from the mold. Manufacturing method of molded products.

[0047] According to the manufacturing method of the molded product having the above-mentioned configuration [4], in the molding process, the surfaces of the plate and the sealing member are vulcanized to form an adhesive layer, so that the sealing member can be made adhesive when the plate of the molded product is peeled off.

[0048] [5] The method further includes a heating step of heating the mold before the material charging step. The method for producing a molded article according to [4] above.

[0049] According to the manufacturing method of molded products configured as above in [5], the mold is heated in advance and the mold is maintained at a temperature similar to that during molding, and the material is then poured into the mold to produce the molded product. This eliminates the need to heat the mold each time material is poured into the mold, and allows for rapid production of molded products. This allows for efficient continuous production of molded products.

[0050] [6] The method further includes a heating step of heating the mold after the material charging step. The method for producing a molded article according to [4] above.

[0051] [7] The method further includes a secondary vulcanization step of heating the molded product after the removal step. A method for producing a molded article according to any one of [4] to [6] above.

[0052] [8] In the molded product according to the above [1] or [2], a peeling step (see FIG. 8) of peeling the plate from the sealing member to expose the adhesive layer (53); The exposed adhesive layer faces the housing body (17) (see FIG. 9), and the sealing member is pressed against the housing body to assemble the sealing member to the housing body. A method for manufacturing a housing (13).

[0053] According to the manufacturing method of the housing having the above-mentioned configuration [8], the sealing member can be assembled to the housing body by peeling off the plate from the sealing member in the molded product to expose the adhesive layer, and pressing the exposed adhesive layer against the housing body. Therefore, compared to, for example, a case where a pin provided on the housing is passed through a pin hole in the sealing member to hold the seal, the number of processing steps can be reduced. [Explanation of symbols]

[0054] 11 Terminal block 13. Housing 15 terminals 17 Housing body 19 Holder 21 Fastening part 23 Assembly section 28 Seal mounting groove 50 sealing material 51 sealing surface 52 Annular seal 53 Adhesive layer 61 Lower mold 62 medium size 63 Upper mold 65 Resin Plate 66 Face seal material 70 Resin plated surface seal

Claims

1. a material introduction step of introducing a material constituting the sealing member into the mold having the plate disposed therein; a molding step of pressurizing the interior to vulcanize the surfaces of the plate and the sealing member to produce a molded product having an adhesive layer formed thereon; and a removal step of removing the molded product from the mold. Manufacturing method of molded products.

2. At least one of the material constituting the plate and the material constituting the sealing member contains an additive for adjusting the adhesion degree of the adhesive layer. A method for producing the molded article according to claim 1.

3. The method further includes a heating step of heating the mold before the material charging step. The method for producing a molded article according to claim 1.

4. The method further includes a heating step of heating the mold after the material charging step. The method for producing a molded article according to claim 1.

5. The method further includes a secondary vulcanization step of heating the molded product after the removal step. A method for producing a molded article according to any one of claims 1 to 4.

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