This application is claims the benefit of priority from Japanese Patent Application No. 2019-150625, filed on Aug. 20, 2019. The contents of the application are incorporated herein by reference in their entireties.
The present invention relates to an apparatus for producing a plate-like body with a resin frame having a decorative molding provided on the resin frame, the decorative molding being formed of a magnetic member.
Among plate-like bodies for a vehicle window, particularly a plate-like body for an automobile window, for example, a window glass, such as a windshield, a side glass or a rear glass, has a resin frame filling a space between the window glass and an opening for an automobile window integrally provided on a peripheral edge area in many cases. By this resin frame, the window glass is fixed to the opening for the automobile window, and the opening for the automobile window is sealed, and in addition, the design of the outer appearance of the window glass is to be improved.
The resin frame is integrally disposed on a window glass, for example, by applying a primer (adhesive) to a peripheral edge area of the window glass and attaching the peripheral edge area to a mold, and injecting a molten resin into a cavity space of the mold, whereby a plate-like body with a resin frame having the resin frame integrally disposed on a peripheral edge area of a window glass is produced. The present applicant discloses in Patent Document 1 listed below and the like a plate-like body with a resin frame for a window (trade name: MAW (registered trademark: Module Assembly Window) manufactured by AGC Inc.).
Further, on a surface of a resin frame which is visually recognizable from outside, a decorative molding made of a metal is provided for the purpose of decorating or reinforcing the resin frame in some cases. The decorative molding has a continuous or frame-like shape produced by press molding or extrusion and is provided on and along the surface of the resin frame.
Patent Document 2 listed below discloses a technique to integrally dispose a resin frame and a metal molding (corresponding to a decorative molding) on a peripheral edge area of a glass substrate by providing a cavity groove and a molding receiving groove to a molding forming mold for molding a resin frame, disposing the metal molding in the molding receiving groove and injecting a molten resin into the cavity groove.
Patent Document 2 also discloses a technique to attract the metal molding in the molding receiving groove by embedding an electromagnet with a coil in a bottom portion of the molding receiving groove and energizing the coil only when attracting the metal molding.
Patent Document 1: JP-A-2007-313669
Patent Document 2: JP-A-2008-94061
The apparatus for producing a plate-like body with a resin frame disclosed in Patent Document 2, however, could damage or distort a surface of the decorative molding corresponding to a position of the mold where the electromagnetic is embedded when observing a plate-like body with the resin frame as a final product, in some cases. In such cases, a quality problem has occurred.
In consideration of these circumstances, the present invention has been proposed. It is an object of the present invention to provide an apparatus for producing a plate-like body with a resin frame, which is capable of increasing the quality of the plate-like body with a resin frame having a decorative molding provided on the resin frame, the decorative molding being formed of a magnetic member.
To achieve the object, the present invention provides an apparatus for producing a plate-like body with a resin frame to be mounted to a vehicle, a decorative molding formed of a magnetic member being provided on the resin frame, which includes a mold having a cavity space therein for forming a resin frame on a plate-like body, the mold further including a first mold formed of a non-magnetic member and having a mounting surface, the mounting surface being configured to have a decorative molding mounted thereon; and a magnet disposed on a surface of the first mold opposite to the mounting surface and configured to retain, on the mounting surface, the decorative molding to be mounted on the mounting surface.
According to the present invention, it is possible to increase the quality of a plate-like body with a resin frame having a decorative molding thereon, the decorative molding being formed of a magnetic member.
Now, the process for producing a plate-like body with a resin frame according to an embodiment of the present invention will be described with reference to the accompanying drawings.
The window glass 12 may be made of inorganic glass or organic glass. As the inorganic glass, soda-lime glass, aluminosilicate glass, borosilicate glass, non-alkali glass or quartz glass may be, for example, used without particular limitation. The window glass 12 is preferred to be made of inorganic glass from the viewpoint of laceration resistance, especially the window glass is preferred to be made of soda-lime glass from the viewpoint of moldability. When the window glass 12 is made of soda-lime glass, clear glass, green glass containing at least a certain amount of iron component, or UV cut green glass may be preferably used. The window glass 12 may be made of privacy glass having at most 70% of visible light transmission (also called dark grey glass). Specifically, the content of total iron calculated as Fe2O3 in the window glass 12 may be controlled to set the visible light transmission of the window glass 12 at at most 70%.
As one example, the privacy glass may have a base glass composition of, in % by mass based on oxides, SiO2: 66 to 75%, Na2O: 10 to 20%, CaO: 5 to 15%, MgO: 0 to 6%, Al2O3: 0 to 5%, K2O: 0 to 5%, FeO: 0.13 to 0.9%, total iron as represented by Fe2O3: at least 0.8% and less than 2.4%, and TiO2: more than 1% and at most 5%, and further contains 100 to 500 ppm by mass of CoO, 0 to 70 ppm by mass of Se, and 0 to 800 ppm by mass of Cr2O3 relative to the total amount of components of the glass matrix composition, wherein the total amount of CoO, Se and Cr2O3 is less than 0.1% by mass.
It should be noted that the privacy glass is described in detail in WO-A-2015-088026 for example, and the entire disclosure of this publication is incorporated herein by reference in its entirety.
The inorganic glass may be either non-tempered glass or tempered glass. The non-tempered glass is one that is produced by forming molten glass in a plate shape and annealing the formed molten glass. The tempered glass is one that is produced by forming a compressive stress layer in the surface of non-tempered glass.
The tempered glass may be either physically tempered glass, such as glass tempered by air quenching, or chemically tempered glass, for example. When physically tempered glass is used, the glass surface may be tempered by, for example, conducting an operation except annealing to quench a glass plate uniformly heated for bending, from a temperature close to its softening point such that a temperature difference is created between the glass surface and the inside of the glass to form a compressive stress layer in the glass surface.
When chemically tempered glass is used, the glass surface may be tempered by, for example, causing a compressive stress in the glass surface by ion exchange treatment or the like after completion of a bending operation. Or, glass that absorbs ultra-violet rays or infrared rays may be used. Although the tempered glass is preferred to be transparent, a glass plate that is colored to such a degree not to impair transparency may be used.
As the organic glass material, a transparent resin, including polycarbonate, an acrylic resin such as polymethyl methacrylate, polyvinyl chloride and polystyrene may be mentioned.
The window glass 12 may have a scattering prevention film stuck thereon in order to prevent glass pieces from scattering when the window glass 12 is broken.
There is no particular limitation to the shape of the window glass 12. The window glass may be formed in any desired shape or any desired shape having a desired curvature. The window glass 12 may be bent by gravity bending, press bending, roller bending or the like. Although there is no particular limitation to how to form the window glass 12, a glass plate formed by a float process is preferred in connection with an organic glass, for example. When the window glass 12 is formed of an organic glass having a curved shape, the window glass 12 is bent after formation by a float process. Bending is conducted in such a state that glass is softened by heating. The glass has a heating temperature of about 500° C. to about 700° C. during bending.
When the window glass 12 is curved, the window glass may be formed in a single curved shape curved only in a single direction or a complex curved shape curved in two or more directions. When the window glass 12 is curved, the window glass is preferred to be curved so as to be convex toward a vehicle exterior side. When the window glass 12 is curved, the window glass 12 has a radius of curvature of preferably at least 1,000 mm and at most 100,000 mm.
The window glass 12 has a plate thickness of preferably of at least 0.3 mm and at most 5.0 mm, more preferably at least 0.5 mm and at most 3.0 mm, furthermore preferably at least 0.7 mm and at most 1.9 mm.
The window glass 12 may have a dark and opaque optically shielding layer (dark ceramic layer), such as a black optically shielding layer, formed in a strip shape along a peripheral edge area thereof. The optically shielding layer achieves the function of shielding an adhesive applied between the glass plate 12 and the resin frame 14 when the window glass 12 is mounted to an automobile body. The optically shielding layer may be formed by being baked after application of ceramic paste to a surface of the window glass 12. The optically shielding layer has a thickness of preferably at least 3 μm and at most 15 μm. Although there is no particular limitation to the width of the optically shielding layer 30, the width is preferred to be at least 20 mm and at most 300 mm.
The window glass 12 may be laminated glass which has a vehicle exterior side glass plate positioned on a vehicle exterior side and a vehicle interior side glass plate positioned on a vehicle interior side, both plates being bonded via an interlayer. As the interlayer, an interlayer made of polyvinyl butyral (PVB) may be used. When the interlayer is required to have water resistance, the interlayer is preferred to be made of an ethylene-vinyl acetate copolymer (EVA). The interlayer may be made of an acrylic photopolymerizable prepolymer, an acrylic catalyst polymerizable prepolymer, a photopolymerizable prepolymer of acrylic ester and vinyl acetate, polyvinyl chloride or the like. The vehicle exterior side glass plate and the vehicle interior side glass plate may be the same as each other or different from each other in terms of composition, shape or thickness.
The resin forming the resin frame 14 may be a thermoplastic resin, for example. The thermoplastic resin may be, for example, a common thermoplastic resin selected from a polyvinyl chloride resin and a polyolefin-based, polyester-based, polystyrene-based, polyimide-based or polyurethane-based elastomer.
In reference to
The film 20 shown in
Now, an example of the apparatus 30 for producing the window glass 10 with a resin frame according to the embodiment will be described with reference to
As shown in
The non-magnetic member forming the first mold 32 is preferred to be a non-magnetic steel having a magnetic permeability of at most 1.02 [H/m], for example. The non-magnetic steel may be, for example, an austenitic-based stainless steel, a high manganese steel or a high nickel alloy. Aluminum or copper is also applicable. When the resin frame 14 is made of a polyvinyl chloride resin, SUS304 as an austenitic-based stainless steel having a high corrosion-resistance is preferred.
The mounting surface 40 is formed in a part of a concave surface 42 defining the cavity space 38 and is formed in a concave shape along the surface 18A of the main part 18 of the decorative molding 16 (see
The mold 36 also includes an electromagnet 44. The electromagnet 44 is disposed on a side of a rear surface 46 of the first mold 32 opposite to the mounting surface 40 such that the decorative molding 16 mounted on the mounting surface 40 can be retained on the mounting surface 40 by a magnetic force. In other words, the production apparatus 30 according to the embodiment is configured such that the electromagnet 44 is not exposed to the mounting surface 40 and is disposed to be separated from the mounting surface by the first mold 32 as a non-magnetic member. Explanation of the electromagnet 44 will be made later.
The mold 36 also has, as shown in
The first mold 32 and the second mold 34 are disposed so as to be relatively moved forward and backward in a horizontal direction indicated by arrows A in
Each of the first mold 32 and the second mold 34 is formed in a frame shape which has a certain length corresponding to the shape of the peripheral edge area 12A of the window glass 12. The electromagnet 44 shown in
In one example, the electromagnet 44 is disposed at each of three positions corresponding to a first end portion 18B, a second end portion 18C and a bent portion 18D of the main part 18 shown in two-dot chain lines. When the plural electromagnets 44 are disposed at such positions, the main part 18 mounted on the mounting surface 40 can be retained on the mounting surface 40 by a magnetic force without falling out from the mounting surface 40.
In other words, the production apparatus 30 according to the embodiment is an apparatus for forming the resin frame 14 while the window glass 12 is disposed in an approximately vertical direction as mentioned above. For this reason, the production apparatus requires means to retain the main part 18 on the mounting surface 40 without allowing the main part from falling out of the mounting surface 40. The electromagnets 44 are adopted as such means. In order to reliably retain the main part 18 on the mounting surface 40, the electromagnets 44 are disposed at three positions in one example.
In reference to
Each electromagnet 44 includes a core 48, a coil 50, a power source 52 and a switch 54. The core 48 is formed in a column shape having at least a leading end surface 48A and an outer peripheral surface 48B, and the leading end surface 48A is disposed facing the rear surface 46 of the first mold 32.
The rear surface 46 has a magnet supporting portion 56, and the magnet supporting portion 56 has a magnet receiving hole 58 formed therein so as to surround the outer peripheral surface 48B when the core 48 is received in the magnet receiving hole.
In a gap between the magnet mounting hole 58 and the outer peripheral surface 48B is disposed a pipe 60 formed of a non-magnetic member. Thus, a magnetic force is effectively generated from the leading end surface 48A of the core 48. It should be noted that the pipe 60 is one example of a cylindrical non-magnetic member, and that the non-magnetic member may be, for example, a non-magnetic member similar to the first mold 32.
The coil 50 is wound around a columnal portion 48C forming a base portion of the core 48 and is connected to the power source 52 through the switch 54. By this arrangement, when the switch 54 is turned on, a current flows from the power source 52 to the coil 50 to generate the magnetic force at the core 48. The core 48 thus constructed is mounted to the magnet supporting portion 56 by a bolt 62.
The production apparatus 30 according to the embodiment includes the mold 36 having the electromagnets 44 as described above. The production apparatus also includes other devices, such as a conveying device for conveying a decorative mold 16 to the first mold 32, a moving device for relatively moving the first mold 32 and the second mold 34 forward and backward in the horizontal direction, an injection device for injecting molten resin into the cavity space 38 and a discharging device for discharging the window glass 10 with a resin frame from the first mold 32.
Now, explanation will be made about a process to use the production apparatus 30 according to the embodiment to produce the window glass 10 with a resin frame.
First, the first mold 32 and the second mold 34 are set at positions to be relatively apart from in the horizontal direction indicated by the arrows A in
When the main part 18 is mounted on the specified position of the mounting surface 40, the switch 54 for the electromagnets 44 is turned on, causing the core 48 to generate a magnetic force. Thus, the main part 18 is retained at the specified position of the mounting surface 40 by the magnetic force generated by the core 48.
After a primer is applied to the peripheral edge area 12A of the window glass 12, the peripheral edge area 12A is mounted to a specified position of the first mold (see
Then, a molten resin (not shown) is injected into the cavity space 38 through a resin injection gate 64 shown in dotted lines and formed in the second mold 34 to be filled in the cavity space 34. After that, the switch 54 for the electromagnets 44 is turned off, and the first mold 32 and the second mold 34 are relatively moved backward in the horizontal direction indicated by the arrow A. Thus, the window glass 10 with a resin frame shown in
When the window glass 10 with a resin frame thus produced is observed, parts of the decorative molding 16 that correspond to the positions of the electromagnets 44 are not damaged or distorted, and no problem of quality is revealed. This is because the electromagnets 44 are not exposed to the mounting surface 40 and are separated from the mounting surface by the first mold 32 as a non-magnetic member in order to prevent the decorative molding 16 from being brought into contact with the electromagnets and because the first mold 32 has no step. Thus, the production apparatus 30 according to the embodiment can improve the quality of the window glass with a resin frame 10 having the decorative molding 16 formed of a magnetic member.
Although explanation of the embodiment has been made about an example of the production apparatus according to the present invention where the production apparatus 30 with the first mold 32 and the second mold 34 relatively moving forward and backward in the horizontal direction is exemplified, the present invention is also applicable to a production apparatus with the first mold and the second mold relatively moving upward and downward in the vertical direction (hereinbelow, referred to as the other example of the production apparatus). In a case of the other example of the production apparatus, the window glass 12 is disposed between the first mold and the second mold, having the primary surfaces 12B directed to an approximately horizontal direction to ground.
In this case, it should be noted that the installment space of the production apparatus increases in some cases because the mold has a projection area increased when the mold is projected to ground. In contrast, in a case of the production apparatus 30 according to the embodiment, the projection area of the mold 36 that is obtained when the mold is projected on ground decreases in comparison with the other example of the production apparatus. The production apparatus 30 according to the embodiment is preferred to be adopted from the viewpoint of saving the installment space of the production apparatus.
Since the production apparatus 30 according to the embodiment is configured such that the plural electromagnets 44 (three electromagnets as an example) are disposed at certain intervals in the longitudinal direction of the first mold 32, the decorative molding 16 can be effectively retained on the mounting surface 40. The electromagnets 44 can be disposed at positions shown in
Since the production apparatus 30 according to the embodiment is configured such that the cores 48 are received in the magnet mounting holes 58 of the magnet supporting portion 56 of the first mold 32, the leading end surfaces 48A of the cores 48 can be reliably positioned to confront the rear surface 46.
Since the production apparatus 30 according to the embodiment has the pipes 60 formed of a non-magnetic member disposed between the outer peripheral surfaces 48B of the cores 48 and the magnet mounting holes 58, the magnetic force can be generated effectively from the leading end surfaces 48A of the cores 48.
Although explanation of the production apparatus 30 according to the embodiment has been made about a case where the electromagnets 44 are used as magnets, permanent magnets are also applicable instead of electromagnets 44.
From the viewpoint that the main part 18 is prevented from being retained at a position shifted from the specified position of the mounting surface 40 by the magnetic force from the permanent magnets, it is preferred to adopt, as the magnets, the electromagnets 44 of capable of being switched between on and off.
Although explanation of the embodiment according to the present invention has been made as above, the present invention is not limited to the above-mentioned embodiment and examples. It will be apparent that many modifications and variations may be made without departing from the spirits or scope of the present invention.
Number | Date | Country | Kind |
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2019-150625 | Aug 2019 | JP | national |