Deformation-free molded article

Abstract: Molded article which is formed of a thermoplastic or thermosetting resin and has two planes (12,10) joining each other in a junction portion (14), at least one of the two planes having an opening portion (20) or thin wall portion in the vicinity of the junction portion.

Description: The present invention relates to molded articles which are almost free of deformation, i.e., warpage and bending, and are formed of a thermoplastic resin or a thermosetting resin. Such molded articles include automobile door mirror stays, automobile door glass holders, housings, IC boxes and chassis of copying machines. These molded articles have at least two planes which form a constant angle. These two planes join each other in a junction portion, and the junction portion may be chamfered. A variety of molded articles are produced from polymer materials or composite materials containing polymers as matrix (hereinafter simply referred to as "raw materials" in some cases) by means of an injection molding machine or a compression molding machine. Most of these molded articles have at least one combination of two planes which join each other in a junction portion. These planes respectively have a constitution of a flat surface and/or a curved surface. Two planes which join each other show deformation such as warpage and bending (hereinafter simply referred to as "deformation" in some cases) in a molding time, and there are many cases where molded articles no longer satisfy a dimensional standard. The form of two planes which join each other in a junction portion and/or the angle formed by the two planes is determined by the forms of cavity wall surfaces of a mold used with an injection molding machine or a compression molding machine and/or an angle formed by the cavity wall surfaces. Actually, however, molded articles show warpage or bending due to contraction of raw materials when produced and other causes. That is, there is caused a difference between a molded article expected from the form of a mold cavity and a molded article actually produced with the mold cavity. This difference is referred to as warpage or bending. Figure 9 of the accompanying drawings shows a state of the above difference. That is, Figure 9 is a schematic cross-sectional view of a moulded article, in which two planes 10 and 12 join each other in a junction portion 14, a dotted line shows a designed cross-sectional form, and a solid line shows the cross sectional form of a moulded article. The cross-sectional form of the moulded article deviates from the designed cross-sectional form due to warpage or bending. It is considered that the deformation is caused by cooling and solidification in a moulding process when the raw material is a thermoplastic resin, and that it is caused by a chemical change in a moulding process when the raw material is a thermosetting resin. For avoiding the deformation, the following methods (A) to (C) have been conventionally employed. (A) A method using a raw material whose shrinkage factor in a moulding process is small. (B) A method in which the radius of curvature of a junction portion is increased so that a shrinkage stress and strain in a junction portion decrease in a moulding time. (C) A method in which a moulded article has a rib to prevent warpage and bending. However, the method (A) cannot be applied in some cases for the following reasons. (a) A raw material is required to have a high elastic modulus and high strength in many cases. (b) The cost of a raw material is required to be decreased in many cases from the economical viewpoint. Further, in many cases, the method (B) or (C), if used alone, is not sufficient to effectively decrease deformation such as warpage and bending. For example, JP-A-64-11219 discloses a rotary polygon mirror for use in an optical apparatus having a laser scanning system. This rotary polygon mirror is formed of a plurality of mirror face portions 11, a boss portion 13, plate-like portions 14 connecting the mirror face portions and the boss portion and a plurality of rib portions 15 extending perpendicularly from in-plane areas of the plate-like portions and connecting the mirror face portions and the boss portion. This rotary polygon mirror is molded by injecting a resin material through a plurality of pinpoint gates 20. Hole portions 30 are formed in junctions where the mirror face portions 11 and the rib portions 15 in the plate-like portions 14 join. Each of the hole portions 30 functions to overcome the fluctuation of a weldline position. That is, the hole portions are formed to control the flow direction (melt front) of a molten resin injected through the pinpoint gates 20 and to control the molding pressure of a resin material acting on the mirror face portions 11 and junction portions 11A of the mirror face portions 11. Due to the above hole portions 30, the weldline can be positioned in the mirror face portions 11, particularly in the junction portion 11A of each mirror face portion 11 even if the pressures of injection from neighboring pinpoint gates 20 vary to some extent. Since, however, these hole portions 30 are not positioned in the vicinity of junctions where the mirror face portions 11 and the plate-like portions 14 join, the hole portions 30 do not serve to prevent the deformation of each of the mirror face portions 11 and the plate-like portions 14. JP-A-64-11220 also discloses a rotary polygon mirror for use in an optical apparatus having a laser scanning system. This rotary polygon mirror 10 is formed of a plurality of mirror face portions 11, a boss portion 13, plate-like portions 14 connecting the mirror face portions and the boss portion, and a plurality of rib portions 15 extending perpendicularly from in-plane areas of the plate-like portions and connecting the mirror face portions and the boss portion. This rotary polygon mirror is produced by injection-molding a resin material through pinpoint gates 20. The thickness of each mirror face portions 11 gradually increases from the central portion to end portions. When each mirror face portion 11 is provided with a thickness which gradually increases or decreases as above, the molding pressure can be uniformly applied to any position of each mirror face portion, whereby the mirror face portions are improved in plane accuracy. However, no thin wall portions are formed in the vicinity of junctions where the mirror face portions 11 and the plate-like portions 14 join. The above gradual increase or decrease in the thickness of each mirror face portion 11 does not serve to prevent the deformation of each of the mirror face portions 11 and the plate-like portions 14. JP-A-3-159717 discloses an optical reflection mirror formed of a synthetic resin, which has two planes joining each other to form an angle. This optical reflection mirror is provided with a reinforcing wall for the reinforcement of a corner formed by the two planes. However, no means are disclosed of modifying the planes per se for preventing the deformation of these two planes, e.g., providing the planes with an opening portion or with a thin wall portion. Japanese Utility Model Publication No. 2-41081 discloses an automobile door mirror produced by aluminum die casting. In this door mirror, a reinforcing partition wall 6a or 60a formed in a base 20 is provided with a securing hole 9 or securing holes 9a and 9b, and a harness 5 is held through the securing hole(s). However, the above publication describes nothing concerning the prevention of the deformation by forming an opening portion or a thin wall portion in the vicinity of a junction where the base 20 and the reinforcing partition wall 6a or 60a join. GB-A-2 097 713 and GB-A-2 209 702 disclose injection moulded products in which distortion between two angled walls is reduced by providing a groove along the joint between the two walls. This enables quicker cooling of the inside of the junction portion. According to the present invention, there is provided a moulded article formed of a thermoplastic resin or a thermosetting resin, having two planes joining each other in a junction portion and comprising a rib, extending along the inner and/or outer surfaces of the two planes from an in-plane area of one plane through the junction portion to an in-plane area of the other plane, characterised in that at least one of the two planes has a relieving portion formed of an opening portion in the vicinity of the junction portion. Thus at least one of the two planes has an opening portion in the vicinity of the junction portion. That is, the opening portion may be provided in one plane in the vicinity of the junction portion, or it may extend from an in-plane area of one plane to the junction portion. It is a preferred embodiment that the opening portion extends from an in-plane area of one plane through the junction portion to an in-plane area of the other plane. A plurality of opening portions may be provided along the junction portion. The opening portion formed in a moulded article as described above can reduce a portion which causes deformation such as warpage and bending, and can also decrease a difference between the raw material cooling rate inside the two planes and the raw material cooling rate outside the two planes in the vicinity of the junction portion, whereby the deformation of the moulded article can be decreased. In a more preferred embodiment of the present invention, the length of the opening portion along the junction portion is 1/10 to 10/10, preferably 3/10 to 10/10, more preferably 5/10 to 10/10, of the length of the junction portion. When the above length is less than 1/10 of the length of junction portion, there is little effect on the deformation prevention. When the length of the opening portion along the junction portion is 10/10 of the length of the junction portion, it means that the two planes are connected with a rib. The angle formed by the rib and the plane (gradient of rib) is 30 to 90°, and the thickness of the rib is preferably 0.5 mm to 10 mm. When the angle formed by the rib and the plane is less than 30°, the effect of the rib on preventing the deformation such as warpage and bending is low, and there is required a mould having a complicated structure. When the thickness of the rib is less than 0.5 mm, the effect of the rib on preventing the deformation is low. When this thickness exceeds 10 mm, the moulding cycle disadvantageously takes a longer time. The thickness of one of the planes may be the same as, or different from, the thickness of the other. The planes may have a flat surface or a curved surface. The junction portion may have a predetermined radius of curvature. The thermoplastic resin and the thermosetting resin used in the present invention can be any thermoplastic resin and any thermosetting resin if they can be moulded with an injection moulding machine or a compression moulding machine. In particular, the present invention can effectively reduce the deformation of a moulded article which is produced from a resin having a high shrinkage factor. The thermoplastic resin and the thermosetting resin used in the present invention may contain a filler. The filler may have the form of beads, fibres or flakes. The filler may be selected from carbon, glass and the like, which are usually incorporated into general injection-moulding resins. These resins used in the present invention may further contain a stabilizer and a pigment, if necessary. The moulded article according to the present invention can be produced from a thermoplastic resin, a thermosetting resin, a thermoplastic resin containing a filler or a thermosetting resin containing a filler by a variety of moulding methods such as an injection moulding method and a compression moulding method. The thermoplastic resin used in the present invention is not specially limited, and it includes not only general-purpose plastics typified by polyolefin resin, a polystyrene resin, an ABS resin, an AS resin, a PVC resin, a methacrylic resin and a fluorine-containing resin but also engineering plastics typified by a nylon resin, a saturated polyester resin, a polycarbonate resin, a polyacrylate resin, a polyacetal resin, a polysulfone resin and a modified polyphenylene ether resin. The thermosetting resin used in the present invention is not specially limited, and it includes a phenolic resin, a furan resin, a xylene·formaldehyde resin, a ketone·formaldehyde resin, a urea resin, a melamine resin, aniline resin, an alkyd resin, an unsaturated polyester resin and an epoxy resin. The conditions for producing the moulded article of the present invention, e.g., an amount of a molten resin, a temperature, a pressure and a time for cooling a mould, cannot be uniformly determined, and these conditions need to be properly selected and controlled depending upon what resin is used and what form the mould has. A variety of parameters such as the forms, sizes and numbers of the opening portion(s) and the form, size and number of the rib(s) are not uniformly determined, either. These parameters are properly determined depending upon the form and cross sectional form of a moulded article and a raw material to be used. These parameters are to be changed depending upon the form and size of a moulded article, the strength required of a moulded article, the kind of a resin to be used, the use or non-use of an additive and the shrinkage factor of a raw material in moulding, and it is therefore required to optimize these parameters according to these conditions. When these parameters are optimized, the deformation of a moulded article such as warpage and bending can be very effectively reduced. According to the present invention, therefore, there can be industrially produced moulded articles required to have high dimensional standard such as an automobile door mirror stay, an automobile door glass holder, a housing, an IC box and a chassis of a copying machine. For example, an automobile door mirror stay of the present invention moulded from a thermoplastic resin has two planes which join each other in a junction portion and ribs, in which one plane constitutes a mirror fitting portion, the other plane constitutes a portion to be fixed to an automobile body, at least one of the two planes has an opening portion in the vicinity of the junction portion, and the ribs are extending along the inner and/or outer surfaces of the two planes from an in-plane area of one plane through the junction portion to an in-plane area of the other plane. In the above door mirror stay, the length of the opening portion along the junction portion is preferably 1/10 to 10/10 of the length of the junction portion. Further, the angle formed by the rib and the plane (gradient of rib) is preferably 30 to 90°, and the thickness of the rib is preferably 0.5 to 10 mm. In another example, a box-shaped moulded article of the present invention moulded from a thermoplastic resin has a bottom plane, side planes and junction portions where the bottom plane and the side planes join, in which at least one of these planes has an opening portion in the vicinity of the corresponding junction portion. In the above box-shaped moulded article, the opening portion is preferably extending from an in-plane area of the bottom plane through the junction portion to an in-plane area of the side plane. Further, the rib is formed extending along the inner and/or outer surfaces of the bottom plane and optionally any one of the side planes from an in-plane area of the bottom plane through the junction portion to an in-plane area of the side plane. The length of the opening portion along the junction portion is preferably 1/10 to 10/10 of the length of the junction portion. The above box-shaped moulded article could be a housing, an IC box and a chassis of a copying machine. The invention will be further described by way of example, with reference to the accompanying drawings, in which:- Figures 1, 2 and 3 show moulded articles according to an embodiment of the present invention. Figure 4 shows variations of the moulded articles according to the present invention. Figure 5 shows an application of the moulded article according to the present invention to an automobile door mirror stay. Figure 6 shows a moulded article (automobile door mirror stay) prepared in Comparative Example 1-A. Figure 7 shows an application of the moulded article according to the present invention to a box-shaped moulded article (printer housing). Figure 8 shows a moulded article (printer housing) prepared in Comparative Example 2-A. Figure 9 schematically shows a state of a deformed moulded article. Figures 1 and 2 show a moulded article according to the present invention. This moulded article has two planes 10 and 12 and one junction portion 14. One opening portion 20 is extending from an in-plane area of the plane 10 through the junction portion 14 to an in-plane area of the other plane 12. Further, ribs 24A are extending along the inner surfaces of the two planes 10 and 12 from an in-plane area of the plane 10 through the junction portion 14 to an in-plane area of the other plane 12. Ribs 24B are extending along the outer surfaces of the two planes 10 and 12, from an in-plane area of the plane 10 through the junction portion 14 to an in-plane area of the other plane 12. Figure 1 is a perspective view of this moulded article. Figure 2A is its front view, Figure 2B is its plan view, Figure 2C is its left side view, and Figure 2D is its cross-section showing the opening portion 20. The plane 10 and the plane 12 form an angle of about 120°. The ribs 24A and 24B and the plane 10 form angles of 90°, and the ribs 24A and 24B and the plane 12 form angles of 90°. Figure 3 shows other moulded articles according to the present invention. The moulded articles' partially cut sections are also shown in Figures 3A and Figure 3B. The moulded article, whose partially cut section is also shown in Figure 3A, has two combinations of planes (planes 10 and 12A; planes 10 and 12B), and two junction portions 14A and 14B. The two planes 10 and 12A join each other in the junction portion 14A, and the two planes 10 and 12B join each other in the junction portion 14B. A plurality of opening portions 20 are extending from an in-plane area of the plane 10 through the junction portion 14A to an in-plane area of the plane 12A. Further, a plurality of opening portions 20 are extending from an in-plane area of the plane 10 through the junction portion 14B to an in-plane area of the plane 12B. Some of the ribs 24B outside the planes are not shown for simplification of the drawing. Figure 4 shows the schematic cross sections of opening portions of moulded articles according to the invention. Figure 4A shows an embodiment in which an opening portion 20 is formed in one plane in the vicinity of a junction portion 14 where the plane joins another plane. Figure 4B shows an embodiment in which an opening portion 20 is extending from an in-plane area of one plane to a junction portion 14. Figure 4C shows an embodiment in which an opening portion 20 is extending from an in-plane area of one plane through a junction portion 14 to an in-plane area of the other plane. As shown in Figure 4C, the junction portion may be chamfered. That is, the junction portion may have a predetermined radius of curvature. One of the outer and inner surfaces of the junction portion may be chamfered. Example 1 A moulded article according to the invention was applied to an automobile door mirror stay. A moulded article (automobile door mirror stay) was produced by injection-moulding a resin composition prepared by blending 45 parts by weight of poly-m-xylylenediadipamide (Reny N252, supplied by Mitsubishi Gas Chemical Company, Inc.) and 55 parts by weight of a glass fibre according to a conventional method. Figure 5 schematically shows the above-produced automobile door mirror stay. Figure 5A is a front view of the automobile door mirror stay, Figure 5B is its left side view, and Figure 5C is its bottom view. In Figure 5, numeral 50 indicates opening portions, numeral 52 indicates inner ribs (thickness: 2 mm), numeral 54 indicates outer ribs (thickness: 2 mm), numeral 56 indicate one plane (thickness: 3 mm) as a mirror fitting portion, numeral 58 indicate other plane (thickness: 3 mm) as a portion to be fixed to an automobile body, numeral 60 indicates holes for mirror fitting bolts, numeral 62 indicates holes through which bolts for fixing the stay to an automobile body are to be inserted, numeral 64 indicates a junction portion where one plane as the mirror fitting portion 56 and the other plane 58 as the portion to be fixed to an automobile body join each other, and numeral 66 indicates outer ribs formed on the portion 58 to be fixed to an automobile body. As shown in the side view of Figure 5B, the plane 56 as the mirror fitting portion and the other plane 58 as the portion to be fixed to an automobile body were to form an angle of 105° (which was an angle expected from a mould cavity design, and the moulded article was to show some deviation). As shown in the front view of Figure 5A, the mirror fitting portion 56 jointed the portion 58 to be fixed to an automobile, in such a state that the mirror fitting portion 56 tilted leftward at an angle of 110° from said portion 58. That is, the ribs and the one plane (mirror fitting portion 56) formed an angle of 80°. In Figure 5A, the mirror fitting portion 56 had a maximum height of 80 mm when measured upwardly from the portion 58 to be fixed to an automobile. Said portion 58 had a width of 100 mm when measured horizontally in this Figure. The smallest width of said portion 58 was 50 mm. In Figure 5C, the pentagonal portion 58 to be fixed to an automobile body had heights of 80 mm and 40 mm when measured vertically in the Figure. Each of the opening portions 50 was formed between the two neighbouring members of the four inner ribs 52. As shown in Figure 5A, each opening portion had a height (in the vertical direction) of 3 mm and a length (in the horizontal direction) of 10 mm. Each opening portion 50 did not extend so far as the junction portion 64 and the portion 58 to be fixed to an automobile body. In Figure 5A, the centres of the inner ribs 52 were positioned 5.75 mm, 15.75 mm, 25.75 mm and 35.75 mm apart from the left end of the portion 58 to be fixed to an automobile body. In Figure 5B, each inner rib 52 had a width (in horizontal direction) of 25 mm and a height, on the right side, of 30 mm. As shown in Figure 5C, the outer ribs 66 on the portion 58 to be fixed to an automobile body were positioned at equal intervals of 12 mm, and the most leftward one was positioned 8 mm apart from the left end of said portion 58. The number of the outer ribs 66 was eight. In Figure 5B, the outer ribs 54 on the mirror fitting portion 56 had a smallest width of 4 mm and a largest width of 6 mm. The outer ribs 66 on the portion 58 to be fixed to an automobile body had a height of 6 mm. Some of the outer ribs 66 on said portion 58 and the outer ribs 54 on the mirror fitting portion 56 were integrally formed. As shown in Figure 5, an automobile door mirror stay has a form in which two planes (mirror fitting portion 56 and the portion 58 to be fixed to an automobile body) join each other in the junction portion 64, and a number of parts are installed on the automobile door mirror stay. Therefore, the tolerance of the deformation such as warpage and bending for the moulded article is very small. The above-produced automobile door mirror stay was measured for warpage. As shown in the left side view of Figure 5B, the warpage was expressed by an angle formed by the portion 58 to be fixed to an automobile body and the mirror fitting portion 56 with the junction portion as a centre. The found angle was 104.9° when the designed angle was 105°. Comparative Example 1-A An automobile door mirror stay was produced from the same resin composition as that used in Example 1 by an injection moulding method in the same manner as in Example 1 except that no opening portions and no ribs were formed. Figure 6A shows a front view of the automobile door mirror stay, Figure 6B shows its left side view and Figure 6C shows its bottom view. This automobile door mirror stay was measured for warpage in the same manner as in Example 1 to show 103.9°. Comparative Example 1-B A moulded article was produced from the same resin composition as that used in Example 1 in the same manner as in Comparative Example 1-A except that the radius of curvature (outer diameter) of its junction portion was increased to 10 mm so that the shrinkage stress and strain decreased in the moulding time. The resultant moulded article was measured for warpage in the same manner as in Example 1 to show 104.1°. That is, the moulded article in this Comparative Example 1-B showed an improved warpage value over the moulded article in Comparative Example 1-A. However, it was not so improved in warpage as the moulded article in Example 1. Comparative Example 1-C An automobile door mirror stay as shown in Figure 5 was produced from the same resin composition as that used in Example 1 in the same manner as in Example 1 except that no opening portions were formed. That is, this automobile door mirror stay differed from that produced in Comparative Example 1-A in that this automobile door mirror stay had ribs. The so-produced automobile door mirror stay was measured for warpage to show 104.4°. That is, the moulded article in this Comparative Example 1-C showed an improved warpage value over the moulded article in Comparative Example 1-B. However, it was not so improved in warpage as the moulded article in Example 1. The above results show that an automobile door mirror stay to which a moulded article according to the present invention is applied has remarkably improved form accuracy over conventional ones, and is remarkably improved in fitting parts such as a motor and a mirror. Example 2 A moulded article according to the present invention was applied to a box-shaped moulded article; a printer housing. A printer housing was produced by injection-moulding a resin composition prepared by blending 80 parts by weight of a polycarbonate resin (trade name: Iupilon GS2020, supplied by Mitsubishi Gas Chemical Company, Inc.) and 20 parts by weight of a glass fibre according to a conventional method. Figure 7A shows a cross-sectional view of the above-produced printer housing, taken at a height of 3/4 of the overall height. In the printer housing, a first plane 70 had a length of 800 mm, a second plane 72 and a fourth plane 76 had a length of 400 mm, a third plane 74 had a length of 660 mm, the thickness of each plane had a thickness of 6 mm, and each plane had a height of 70 mm. An L-letter-shaped concave portion having a size of 70 mm x 50 mm was formed in each of a corner formed by the second plane 72 and the third plane 74 and a corner formed by the fourth plane 76 and the third plane 74. As shown in a perspective view of part of the moulded article in Figure 7B, each rib (thickness 2 mm) was formed, for example, in such a manner that an inner rib 24A and an outer rib 24B were integrally formed. That is, the ribs were formed inside and outside the side plane 70 and a bottom plane 78, inside and outside the side plane 72 and the bottom plane 78, inside and outside the side plane 74 and the bottom plane 78, and inside and outside the side plane 76 and the bottom plane 78. The ribs had a form shown in a side view of Figure 7C. In the side view of Figure 7C, the corner in the left bottom of the outer rib 24B had a right angle, the height on the left side was 30 mm, the length of the bottom side was 40 mm, the length on the upper side was 20 mm, the height on the right side was 8 mm, and the length of a horizontal portion toward the right end was 14 mm. Each of opening portions 20 was formed between the two neighbouring members of the ribs 24A and 24B. Each opening portion 20 was extending from an in-plane area of one plane (bottom plane) to an in-plane area of the other plane (first, second, third or fourth plane). The opening portion 20 shown by a dotted line for a convenience sake in Figure 7C had a height of 20 mm and a width of 18 mm. The first plane had 39 ribs, each of the second and fourth planes had 19 ribs, and the third plane had 19 ribs. These ribs were formed at equal intervals. The moulded article was measured for a maximum distance between a top portion of the third plane and an imaginary line from one top end portion of the third plane to the other top end portion thereof, and this maximum distance was taken as warpage. The warpage was 2.0 mm in the inward direction. Comparative Example 2-A A printer housing was produced by injection-moulding the same resin composition as that used in Example 2 in the same manner as in Example 2 except that no opening portions and no ribs were formed (see a perspective view in Figure 8). This moulded article showed an inward warpage of 4.5 mm. Comparative Example 2-B A moulded article was produced by injection-moulding the same resin composition as that used in Example 2 in the same manner as in Comparative Example 2-A except that the radius of curvature (outer diameter) of its junction portions was increased to 10 mm so that the shrinkage stress and strain in the junction portions (where the first, second, third and fourth planes respectively joined the bottom plane) decreased in the moulding time. The resultant moulded article was measured for warpage in the same manner as in Example 2 to show 4.0 mm in the inward direction. Comparative Example 2-C A printer housing was produced by injection-moulding the same resin composition as that used in Example 2 in the same manner as in Example 2 except that no opening portions were formed. That is, the same ribs as those in Example 2 were formed outside and inside each plane. This moulded article showed a warpage of 3.5 mm in the inward direction. A printer housing is a box-shaped moulded article, and one of its big problems is warpage. Since a number of parts are mounted on the printer housing, the tolerance of the deformation such as warpage and bending for the printer housing is very small. According to the present invention, the deformation can be remarkably reduced by forming an opening portion and a rib. Therefore, the printer housing according to the present invention can be remarkably improved in form accuracy as compared with conventional ones, and as a result, a motor, a gear, an IC-mounted printed circuit board, etc., can be remarkably easily installed. The moulded articles as embodiments according to the present invention show a great decrease in the deformation such as warpage and bending as compared with conventional moulded articles. The moulded articles as embodiments according to the present invention can show a great decrease in warpage even if they are produced from raw materials showing a great property change in moulding (raw materials having a high shrinkage factor in moulding). Therefore, a variety of moulded article required to have high dimensional accuracy can be supplied to a variety of industrial fields at a low cost.

Claims: A moulded article formed of a thermoplastic resin or a thermosetting resin, having two planes (10,12) joining each other in a junction portion (14) and comprising a rib (24A), extending along the inner and/or outer surfaces of the two planes (10,12) from an in-plane area of one plane (10) through the junction portion (14) to an in-plane area of the other plane (12), characterised in that at least one of the two planes (10,12) has a relieving portion (20) formed of an opening portion (20) in the vicinity of the junction portion (14). A moulded article according to claim 1, wherein the relieving portion (20) extends from an in-plane area of one plane (10) through the junction portion (14) to an in-plane area of the other plane (12). A moulded article according to claim 1 or 2, wherein the relieving portion (20) has a length, along the junction portion (14), of 1/10 to 10/10 of a length of the junction portion (14). An automobile door mirror stay comprising a moulded article according to any one of the preceding claims, one of the planes (56) constituting a mirror fitting portion, the other of the planes (58) constituting a portion to be fixed to an automobile body. An automobile door glass holder comprising a moulded article according to any one of the claims 1 to 3, having as said planes (56,58) a bottom plane and two side planes joining the bottom plane in junction portions (64), the two side planes being substantially parallel with each other, a piece of automobile door glass being placed in a space defined by the bottom plane and the two side planes. A moulded article according to any one of claims 1 to 3, having as said planes a bottom plane (78), side planes (70-76) and junction portions where the side planes (70-76) join the bottom plane (78), to form a box-shaped moulded article.

Inventors: ITAGAKI YUKO, KAYANO YOSHIHIRO, NARAZAKI NORIO, UKAJI RYOJI, ITAGAKI, YUKO, KAYANO, YOSHIHIRO, NARAZAKI, NORIO, UKAJI, RYOJI                                     D, Itagaki, Yuko, c/o Plastics Technology Centre, Kayano, Yoshihiro, c/o Plastics Tech. Centre, Narazaki, Norio, c/o Plastics Technology Centre, Ukaji, Ryoji, c/o Isehara Plant, Ichikoh Ind., Ltd
Applicants: ICHIKO INDUSTRIES LTD, MITSUBISHI GAS CHEMICAL CO, ICHIKOH INDUSTRIES LIMITED, MITSUBISHI GAS CHEMICAL COMPANY, INC.
Application year: 1992
Main classification: B29C37
IPC codes: B29C37, B60R1, B29C45, B29C33