U.S. patent application number 09/942033 was filed with the patent office on 2002-03-14 for air conditioner outlet vent device.
Invention is credited to Baba, Hideki, Higuchi, Junichi, Ishida, Yutaka, Koike, Takashi, Tabuchi, Akira, Tsujikawa, Yozaburo.
Application Number | 20020031999 09/942033 |
Document ID | / |
Family ID | 18753162 |
Filed Date | 2002-03-14 |
United States Patent
Application |
20020031999 |
Kind Code |
A1 |
Baba, Hideki ; et
al. |
March 14, 2002 |
Air conditioner outlet vent device
Abstract
An air conditioner outlet vent device 1 in which one of a blade
and a housing is molded as a primary molding having a shaft hole by
primary injection using a first synthetic resin, the other is
molded, within a secondary mold die where the primary molding has
been set, as a secondary molding having a support shaft by
secondary injection using a second synthetic resin so that the
shaft hole and the support shaft are fitted together at the same
time as they are molded, thereby enabling the blade to pivot within
the housing. The first and second synthetic resins are of the same
synthetic resin system, and an additive for suppressing shrinkage
in cooling and solidifying it after injection molding is added to
the first synthetic resin so that the percentage mold shrinkage of
the shaft hole becomes smaller than that of the support shaft.
Inventors: |
Baba, Hideki; (Gunma,
JP) ; Ishida, Yutaka; (Gunma, JP) ; Koike,
Takashi; (Gunma, JP) ; Higuchi, Junichi;
(Gunma, JP) ; Tabuchi, Akira; (Tokushima, JP)
; Tsujikawa, Yozaburo; (Tokushima, JP) |
Correspondence
Address: |
ARENT FOX KINTNER PLOTKIN & KAHN
1050 CONNECTICUT AVENUE, N.W.
SUITE 600
WASHINGTON
DC
20036
US
|
Family ID: |
18753162 |
Appl. No.: |
09/942033 |
Filed: |
August 30, 2001 |
Current U.S.
Class: |
454/155 ;
454/319 |
Current CPC
Class: |
B60H 1/3428
20130101 |
Class at
Publication: |
454/155 ;
454/319 |
International
Class: |
B60H 001/34; F24F
007/00; F24F 013/06; F24F 013/14 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 30, 2000 |
JP |
2000-265988 |
Claims
What is claimed is:
1. An air conditioner outlet vent device in which one of a blade
and a housing that surrounds the blade is molded as a primary
molding having a shaft hole by primary injection using a first
synthetic resin, the other of the blade and the housing is molded,
within a secondary mold die where the primary molding has been set,
as a secondary molding having a support shaft corresponding to the
shaft hole by secondary injection using a second synthetic resin so
that the shaft hole and the support shaft are fitted together at
the same time as they are molded, thereby enabling blade to pivot
within the housing, wherein: the first and second synthetic resins
are of the same synthetic resin system, and an additive for
suppressing shrinkage of the primary molding in cooling and
solidifying it after injection molding is added to the first
synthetic resin so that the percentage mold shrinkage of the shaft
hole becomes smaller than that of the support shaft.
2. An air conditioner outlet vent device in which one of a blade
and a housing that surrounds the blade is molded as a primary
molding having a shaft hole by primary injection using a first
synthetic resin, the other of the blade and the housing is molded,
within a secondary mold die where the primary molding has been set,
as a secondary molding having a support shaft corresponding to the
shaft hole by secondary injection using a second synthetic resin so
that the shaft hole and the support shaft are fitted together at
the same time as they are molded, thereby enabling the blade to
pivot within the housing, wherein: the first and second synthetic
resins are of the same synthetic resin system, an additive for
suppressing shrinkage of the primary and secondary moldings in
cooling and solidifying them after injection molding is added to
each of the first and second synthetic resins at deferent ratios of
the amounts of the additive added to the two synthetic resins so
that the percentage mold shrinkage of the shaft hole becomes
smaller than that of the support shaft.
3. The air conditioner outlet vent device according to claim 2
wherein the primary molding is the housing, the secondary molding
is the blade, and the support shaft formed on the blade does not
protrude from the housing.
4. The air conditioner outlet vent device according to any one of
claims 1 to 3 wherein one of the first and second synthetic resins
is polyethylene and the other is polypropylene.
5. The air conditioner outlet vent device according to any one of
claims 1 to 3 wherein the additive has a function of enhancing the
heat resistance of the molding.
6. The air conditioner outlet vent device according to claim 4
wherein the additive has a function of enhancing the heat
resistance of the molding.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an air conditioner outlet
vent device that is mounted in an instrument panel of an
automobile, etc. and, in particular, to an improvement in an air
conditioner outlet vent device in which either one of a blade or a
housing that surrounds the blade is molded as a primary molding
having a shaft hole by primary injection using a first synthetic
resin, the other one of the blade or the housing is molded within a
secondary mold die, in which the primary molding has been set, as a
secondary molding having a support shaft corresponding to the
above-mentioned shaft hole by secondary injection using a second
synthetic resin so that the shaft hole and the support shaft are
fitted together at the same time as they are molded, and being so
fitted together the blade can pivot within the housing.
[0003] 2. Description of the Related Art
[0004] Such an air conditioner outlet vent device is already known
as disclosed in, for example, Japanese Patent Application Laid-open
No. 10-82554, in which a housing with shaft holes is formed by
primary molding and blades with support shafts are formed by
secondary molding.
[0005] In this conventional device, with regard to the materials
forming the housing and the blade, in order to avoid melt-bonding
between the housing and the blade during secondary molding, they
are made from different synthetic resin materials that are chosen
so that the secondary injection material has a melting point lower
than that of the primary injection material (for example, an ABS
resin for the housing and a polypropylene resin for the blade).
[0006] Furthermore, in this conventional device, taking into
consideration the thermal deformation of the blade, in order to
prevent the blade from dropping out due to its shrinkage, an
surplus shaft section which protrudes from the housing is provided
on the support shaft of the blade.
[0007] However, as in the above-mentioned conventional device, when
materials of different systems are used for the housing and the
blade, a step of separating the housing and the blade is required
for recycling. Taking into consideration the cost and labor of this
step, it is difficult to recycle the material in practice.
[0008] If, taking recycling into consideration, materials of the
same system are used for the housing and the blade, the percentage
mold shrinkage of the shaft hole and that of the support shaft
become approximately equal, and there are the problems that the
support shaft comes into close contact with the shaft hole thus
melt-bonding the two and it is difficult to adjust the feeling
given by pivoting of the blade.
[0009] In particular, in the structure in which an surplus shaft
section is provided on the blade support shaft in order to prevent
the blade from dropping out due to its shrinkage, the surplus shaft
section protrudes from the housing. In particular, in an outlet
vent device of a type in which the air is directed by pivoting the
housing itself relative to a fixed support, there are the problems
that the surplus shaft section might obstruct the pivoting of the
housing and degrade the appearance by being exposed to the
passenger compartment when pivoting the housing.
SUMMARY OF THE INVENTION
[0010] The present invention has been carried out in view of the
above-mentioned circumstances, and it is a main object of the
present invention to provide an air conditioner outlet vent device
in which even when, taking recycling into consideration, a housing
and a blade are made from materials of the same system, the
percentage mold shrinkage of the shaft hole can be made smaller
than that of the support shaft by a simple arrangement so as to
avoid melt-bonding between the shaft hole and the support shaft,
and the feeling given by pivoting of the blade can easily be
adjusted.
[0011] In order to achieve the above-mentioned object, in
accordance with a first aspect of the present invention, there is
proposed an air conditioner outlet vent device in which one of a
blade and a housing that surrounds the blade is molded as a primary
molding having a shaft hole by primary injection using a first
synthetic resin, the other of the blade and the housing is molded,
within a secondary mold die where the primary molding has been set,
as a secondary molding having a support shaft corresponding to the
shaft hole by secondary injection using a second synthetic resin so
that the shaft hole and the support shaft are fitted together at
the same time as they are molded, thereby enabling blade to pivot
within the housing, wherein: the first and second synthetic resins
are of the same synthetic resin system, and an additive for
suppressing shrinkage of the primary molding in cooling and
solidifying it after injection molding is added to the first
synthetic resin so that the percentage mold shrinkage of the shaft
hole becomes smaller than that of the support shaft. In accordance
with the above-mentioned proposed arrangement, even when, taking
recycling into consideration, the housing and the blade are made
from materials of the same system, the percentage mold shrinkage of
the shaft hole can be made smaller than that of the support shaft
by the simple arrangement of merely adding the above-mentioned
additive to the first synthetic resin used for the primary
injection. Therefore, it is possible to effectively prevent
melt-bonding between the shaft hole and the support shaft and,
moreover, by merely controlling the amount of the above-mentioned
additive, the feeling given by pivoting of the blade can easily be
adjusted.
[0012] Furthermore, in accordance with a second aspect of the
present invention, there is proposed an air conditioner outlet vent
device in which one of a blade and a housing that surrounds the
blade is molded as a primary molding having a shaft hole by primary
injection using a first synthetic resin, the other of the blade and
the housing is molded, within a secondary mold die where the
primary molding has been set, as a secondary molding having a
support shaft corresponding to the shaft hole by secondary
injection using a second synthetic resin so that the shaft hole and
the support shaft are fitted together at the same time as they are
molded, thereby enabling the blade to pivot within the housing,
wherein: the first and second synthetic resins are of the same
synthetic resin system, an additive for suppressing shrinkage of
the primary and secondary moldings in cooling and solidifying them
after injection molding is added to each of the first and second
synthetic resins at deferent ratios of the amounts of the additive
added to the two synthetic resins so that the percentage mold
shrinkage of the shaft hole becomes smaller than that of the
support shaft. In accordance with the above-mentioned proposed
arrangement, even when, taking recycling into consideration, the
housing and the blade are made from materials of the same system,
the percentage mold shrinkage of the shaft hole can be made smaller
than that of the support shaft by a simple arrangement of merely
changing the ratio of the amounts of additive added to the first
synthetic resin used for the primary injection and the second
synthetic resin used for the secondary injection. Therefore, it is
possible to effectively prevent melt-bonding between the shaft hole
and the support shaft. Moreover, since the percentage mold
shrinkage of the shaft hole and the support shaft can be changed
individually by adding the additive to the two synthetic resins,
the feeling given by pivoting of the blade can yet more easily be
adjusted.
[0013] Furthermore, in accordance with a third aspect of the
present invention, in addition to the second aspect, there is
proposed an air conditioner outlet vent device wherein the primary
molding is the housing, the secondary molding is the blade, and the
support shaft formed on the blade does not protrude from the
housing. In accordance with the above-mentioned proposed
arrangement, the appearance of the device is improved and its size
is decreased. Therefore, even when this arrangement is applied to
an outlet vent device of, for example, the type in which air is
directed by pivoting the housing itself relative to a fixed support
frame, there is no possibility that the support shaft might
interfere with the pivoting of the housing or the support shaft
might be exposed to a passenger compartment when pivoting the
housing, thus degrading its appearance. Moreover, since the mold
shrinkage of the blade can be controlled to an appropriate level by
adding the above-mentioned additive to the blade, it is possible to
effectively prevent the support shaft from dropping out of the
shaft hole without making the support shaft protrude from the
housing.
[0014] Furthermore, in accordance with a fourth aspect of the
present invention, in addition to the above-mentioned first, second
or third aspect, there is proposed an air conditioner outlet vent
device wherein one of the first and second synthetic resins is
polyethylene and the other is polypropylene. In accordance with the
above-mentioned proposed arrangement, when selecting materials for
the housing and the blade, since a combination of polyethylene and
polypropylene which are general as recycling materials, can be
employed, recycling becomes extremely easy.
[0015] Furthermore, in accordance with a fifth aspect of the
present invention, in addition to the above-mentioned first, second
or third aspect, there is proposed an air conditioner outlet vent
device wherein the above-mentioned additive has a function of
enhancing the heat resistance of the molding. In accordance with a
sixth aspect of the present invention, in addition to the
above-mentioned fourth aspect, there is proposed an air conditioner
outlet vent device wherein the above-mentioned additive has a
function of enhancing the heat resistance of the molding. In
accordance with the above-mentioned proposed arrangements, since
the heat resistance of the molding to which the additive is added
is enhanced, a comparatively inexpensive synthetic resin material
having low heat resistance can be chosen as a material for the
molding, thus reducing the unit cost of the product. For example,
when the molding is a blade that is required to have heat
resistance, a comparatively inexpensive synthetic resin material
having low heat resistance can be chosen as a blade material, thus
reducing the unit cost of the blade.
[0016] The `percentage mold shrinkage` referred to in the present
invention denotes the percentage of the change due to actual
shrinkage of the molding based on reference dimensions obtained on
the assumption that the molding did not shrink at all on cooling
and solidifying after injection molding. The smaller the percentage
mold shrinkage, the smaller the degree of shrinkage, that is to
say, it is described as being difficult to shrink.
[0017] The above-mentioned objects, other objects, characteristics
and advantages of the present invention will become apparent from
explanations of preferred embodiments that will be described in
detail below by reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIGS. 1 to 3 illustrate a first embodiment of the present
invention.
[0019] FIG. 1 is a partially cutaway perspective view of an air
conditioner outlet vent device.
[0020] FIG. 2 is a cross section at line 2-2 in FIG. 1.
[0021] FIG. 3 is a diagram for explaining the molding of a blade by
secondary injection.
[0022] FIG. 4 is a cross section corresponding to FIG. 2 regarding
a second embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] The first embodiment of the present invention is explained
by reference to FIGS. 1 to 3.
[0024] In FIG. 1, 1 denotes an air conditioner outlet vent device
for an automobile of the first embodiment. The air conditioner
outlet vent device 1 has a cylindrical housing 2 molded by primary
injection using a first synthetic resin (e.g. a polypropylene
resin) and a large number of blades 3 molded by secondary injection
within the housing 2, using a second synthetic resin (e.g. a
polyethylene resin) that is of the same system as that of the first
synthetic resin, so as to be arranged side by side. After the
secondary injection molding, all the blades 3 are linked to each
other by a single link 4. The housing 2 is secured to a fixed
support such as an instrument panel for an automobile (not
illustrated), an air supply duct (not illustrated) is connected to
the left-hand end in FIGS. 1 and 2, and air flows in the direction
of arrow A.
[0025] As shown in FIGS. 1 and 2, when molding the housing 2, the
same number of vertical pairs of bosses 5 as the number of blades 3
are formed on the upper and lower walls of the housing 2, and the
bosses are arranged in the lateral direction in such a manner that
their inner ends protrude from the inner surfaces of the housing 2.
Each vertical pair of bosses 5 have coaxial shaft holes 6. These
shaft holes 6 are formed as blind holes in the illustrated example,
and the support shafts 9 which will be described below and fit into
the shaft holes 6, do not therefore protrude from the housing
2.
[0026] Each of the blades 3 has a blade main body 7 and a pair of
upper and lower support shafts 9 provided integrally on the upper
and lower ends of the blade main body 7 so as to project therefrom.
These support shafts 9 fit into the corresponding shaft holes 6 in
a pivotable and slidable manner, which enables the blades 3 to
pivot within the housing 2. A flange 8 having a larger size than
the thickness of the blade main body 7 is formed integrally in a
seamless manner on each of the base ends of the support shafts 9,
the base ends facing inside the housing 2, so as to face and
contact the inner end of the corresponding boss 5.
[0027] Furthermore, a pair of arms 11 which are connected to each
other via a connecting pin 10 are projectingly provided on one side
of the rear end, opposite to the air flow direction A relative to
the support shaft 9, of the blade main body 7. A knob 12 is also
formed on the forward end, in the air flow direction A, of the main
body 7 of one of the blades.
[0028] When molding the large number of blades 3 having the
above-mentioned structure, the housing 2 is molded beforehand by
primary injection using a first synthetic resin in a housing
molding die (not illustrated).
[0029] Next, the thus-molded housing 2 is placed in a blade molding
die 13 as shown in FIG. 3 so that the shaft holes 6 and the inner
end surfaces of the bosses 5 face a cavity 14 within the die 13. A
second synthetic resin is then injected so as to fill the cavity
14. The secondary injection is thus completed, all the blades 3 are
formed in a single step, and the shaft holes 6 and the support
shafts 9 are fitted together at the same time as the molding. After
cooling, the die 13 is opened and the housing 2 is removed from the
die 13 together with the blades 3.
[0030] Subsequently, a large number of C-shaped elastic connectors
4a formed integrally with the link 4 are elastically engaged with
the corresponding connecting pins 10 of the blades 3 so as to link
all the blades 3 to each other. By laterally swinging the single
knob 12 with a fingertip, all the blades 3 can thus be pivoted in
the lateral direction around their respective support shafts 9,
thereby adjusting the direction in which air is blown out of the
housing 2.
[0031] In this first embodiment, as the mold materials for the
housing 2 and the blade 3, materials of the same system that are
general recycling materials, that is to say, a polypropylene resin
and a polyethylene resin, are used in combination, which makes
recycling extremely easy.
[0032] In this first mode of the first embodiment, an additive for
suppressing the shrinkage of a molding when cooled and solidified
after injection molding is added only to the first synthetic resin
(e.g. a polypropylene resin) for primary injection, and the
percentage mold shrinkage of the primary injection molding (i.e.
the shaft hole 6) is thus made smaller than that of the secondary
injection molding (i.e. the support shaft 9). Therefore, in cooling
and solidifying the resin after secondary molding, since the
percentage shrinkage of the support shaft 9 is larger than that of
the shaft hole 6, there is no possibility that the shaft hole 6
might excessively constrict the support shaft 9, and unnecessarily
high surface pressure is not caused between the shaft hole 6 and
the support shaft 9. It is therefore possible to effectively
prevent melt-bonding between the shaft hole 6 and the support shaft
9. Moreover, by merely controlling the amount of the
above-mentioned additive added to the first synthetic resin, the
frictional torque working between the shaft hole 6 and the support
shaft 9 and consequently the feeling given by pivoting (resistance
to pivoting) of the blade 3 can easily be adjusted, whereby the
blade 3 can thus be maintained at an intended position.
[0033] With regard to the above-mentioned additive, any material
can be used as long as it exhibits an effect of suppressing the
above-mentioned shrinkage on cooling and solidifying, when added to
a synthetic resin. For example, at least one material chosen among
talc, glass fiber, potassium titanate, calcium silicate, etc. can
be used as appropriate. Furthermore, a material such as potassium
whose physical properties are not degraded when it is recycled,
titanate fiber, is preferably used as the above-mentioned
additive.
[0034] In particular, with regard to potassium titanate, that
having the form of short fibers is preferred, since the addition
thereof to a synthetic resin can enhance the heat resistance of the
molding, thus increasing its heat resistant temperature. It is
therefore advantageous in satisfying the requirements for heat
resistance in an air conditioner outlet vent device. Furthermore,
addition of potassium titanate can improve the appearance of the
molding, and results in an advantage of enhancing the salability of
the device. In particular, when such a potassium titanate is added
to a resin used for forming the blade 3, an effect of enhancing the
rigidity of the blade 3 can be exhibited, the blade main body 7 can
be made thinner, and reductions in the weight and the cost and an
increase in the outlet vent opening area can thus be achieved.
[0035] In a second mode of the first embodiment, the
above-mentioned additive is added not only to the first synthetic
resin (e.g. a polypropylene resin) used for the primary injection,
but also to the second synthetic resin (e.g. a polyethylene resin)
used for the secondary injection. By changing the ratio of the
amounts of the additive added to the two synthetic resins, the
percentage mold shrinkage of the primary molding (i.e. the shaft
hole 6) is made smaller than that of the secondary molding (i.e.
the support shaft 9). As in the above-mentioned first mode, in
cooling and solidifying the resin after secondary molding, the
percentage shrinkage of the support shaft 9 becomes larger than
that of the shaft hole 6, leading to no possibility that the shaft
hole 6 might excessively constrict the support shaft 9, thereby
effectively preventing melt-bonding between the shaft hole 6 and
the support shaft 9.
[0036] Moreover, since the percentage mold shrinkage of the shaft
hole 6 and that of the support shaft 9 can be changed individually
by adding the additive to the two synthetic resins, the feeling
given by pivoting of the blade 3 can be adjusted yet more easily.
When adjusting this feeling, for example, the amount of additive
that can satisfy the heat resistance requirement for the blade 3 is
first determined and an amount .alpha. is added to the resin
therefor. The amount of the additive used for the housing 2 that is
expected to give the best feeling upon pivoting the blade is then
determined. By changing the amount +.alpha. of additive used for
the blade 3, the feeling given by pivoting can be finely adjusted.
The feeling given by pivoting can thereby be adjusted without
adjusting the amount of additive used for the housing 2 which has a
structure in which it is joined to another part (that is to say,
without changing the shrinkage (dimensions) of the housing 2).
[0037] In the above-mentioned first embodiment, the primary molding
corresponds to the housing 2 and the secondary molding corresponds
to the blade 3. Since the support shaft 9 formed on the blade 3
does not protrude (is not exposed) from the housing 2, the
appearance of the device is improved and its size is decreased. In
this case, if the above-mentioned additive is also added to the
blade 3 as is the case of the above-mentioned second mode, since
the mold shrinkage of the blade 3 can be controlled and suppressed
appropriately, it is possible to effectively prevent the support
shaft 9 from dropping out of the shaft hole 6 without making the
support shaft 9 protrude from the housing 2.
[0038] In particular, when the above-mentioned potassium titanate
is added as the additive to the blade 3 which is required to have
heat resistance, even if a comparatively inexpensive synthetic
resin material having low heat resistance is chosen as a material
for forming the blade 3, the heat resistance required for the blade
3 can be obtained and the unit cost of the product can be
reduced.
[0039] FIG. 4 illustrates a second embodiment of the present
invention. In this embodiment, the invention is applied to an
outlet vent device of the type in which air is directed by
supporting a housing 2 itself around a pivot shaft 15 in a
pivotable manner relative to a fixed support such as, for example,
an instrument panel P of an automobile. The above-mentioned pivot
shaft 15 is placed approximately perpendicular to the support shaft
9, and the housing 2 can be maintained at a required position by
the frictional torque working on the pivoting movement support as
is the case of the blade 3. A hole Pa for receiving the housing 2
in the instrument panel P is formed with a circular surface that
has its center on the above-mentioned pivot shaft 15. The outer
surface of the housing 2 is also formed with a circular surface
approximately following the hole Pa. Since the other structures of
the housing 2 and the blade 3 are basically the same as those in
the first embodiment, the reference numerals and symbols of the
main parts corresponding to the first embodiment are only shown and
their explanation is omitted.
[0040] Also in the second embodiment, the support shafts 9 do not
protrude from the housing 2. Therefore, there is no possibility
that the support shafts 9 interfere with pivoting of the housing 2
around the pivot shaft 15, or the support shafts 9 are exposed to a
passenger compartment upon pivoting of the housing 2 to degrade its
appearance.
[0041] In the above-mentioned embodiments, the housing 2 is chosen
as the primary molding having the shaft hole 6, the blade 3 is
chosen as the secondary molding having the support shaft 9, and
after the housing is formed by primary molding, the blades 3 are
formed by secondary molding. However, in the present invention (the
first and second aspects), a blade can be formed as a primary
molded article having a shaft hole by primary injection using a
first synthetic resin, and a housing can be formed as a secondary
molded article having a support shaft by secondary injection using
a second synthetic resin.
[0042] Furthermore, in the above-mentioned embodiments, the shaft
hole 6 is a blind hole, but in the present invention the shaft hole
6 can be formed as a through hole, and in this case the length of
the support shaft 9 is set so as not to protrude from the shaft
hole 6.
[0043] Furthermore, in the above-mentioned embodiments, with regard
to resins of the same system used for forming the blade and the
housing, olefin system resins, that is to say, homopolymers of
olefin compounds (those represented by the general formula
C.sub.nH.sub.2n and having one double bond (ethylene bond) such as
ethylene, propylene or butylene) are used. However, in the present
invention, two types of resin of the same system that is different
from the olefin system such as, for example, the styrene system,
amide system and PET system may be used in appropriate
combinations. In addition, among combinations of resins that can be
recycled as a mixture, combinations of systems such as a
combination of polyethylene (olefin system) and polystyrene
(styrene system) that cannot be said to belong to the same system
in a strict sense are treated as the `same system` in a broad sense
and may be used in the present invention.
[0044] Although embodiments of the present invention have been
explained above, the present invention is not limited by the
above-mentioned embodiments and can be modified in a variety of
ways.
* * * * *