CN102689439B - 熔敷方法以及熔敷装置 - Google Patents

熔敷方法以及熔敷装置 Download PDF

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CN102689439B
CN102689439B CN201210074242.6A CN201210074242A CN102689439B CN 102689439 B CN102689439 B CN 102689439B CN 201210074242 A CN201210074242 A CN 201210074242A CN 102689439 B CN102689439 B CN 102689439B
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CN102689439A (zh
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提坂裕至
佐藤正和
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Koito Manufacturing Co Ltd
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
    • B29C65/1661—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined scanning repeatedly, e.g. quasi-simultaneous laser welding
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    • B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8126—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
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    • B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8126—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
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Abstract

本发明涉及熔敷方法以及熔敷装置。本发明的熔敷技术系在第一部件(1)上使得具有光透过性的第二部件(2)密接，从第二部件(2)侧照射被偏转控制的激光(L)，在熔敷面(R)熔敷两部件，压板(14)配设在第二部件(2)的光照射面侧，入射角调整阶梯(141)设在压板(14)，构成反射率减少手段，通过该反射率减少手段，减小第一部件(1)和第二部件(2)的在光照射面的光的入射角(θ1，θ2)，减少在光照射面的激光的反射损耗，提高熔敷效率。在通过照射光进行部件熔敷的熔敷技术中，减少照射光的反射损耗，实现熔敷效率高的熔敷。

Description

熔敷方法以及熔敷装置
技术领域
本发明涉及能提高照射激光等光熔敷被加工物时的熔敷效率的熔敷方法以及熔敷装置。
背景技术
作为制造车辆用灯的工序之一，有将透明的前面罩一体地固接在呈容器状的灯体上的工序，作为该固接工序，使用熔敷灯体和前面罩的方法。例如，如图1那样，由前面开口的容器状的灯体1，以及固接在该灯体1的该前面开口的透明树脂制的前面罩2构成灯壳体场合，沿着灯体1的前面开口的周缘，设有凸缘3，使得该凸缘3的前面和前面罩2的周缘部4的内面(在图1中，都用点画表示)密接，将该密接面作为熔敷面，熔敷两者使其一体化。该熔敷时，在专利文献1中，使得用具有光透过性的树脂形成的前面罩以接触状态载置在用光吸收性树脂形成的灯体的前面开口上，通过从前面罩的外面侧对于熔敷面照射激光，用激光的光能量使得该熔敷面熔融，使得两者熔敷。又，这种熔敷时，必须沿着熔敷面照射激光，在专利文献2中，提出以下技术：通过使用X、Y两轴回转反射镜单元、所谓电流镜装置，控制激光偏转，沿着熔敷面使得激光扫描。
作为使用专利文献1及专利文献2的技术制造车辆用灯的灯壳体的熔敷装置，可以使用例如图2所示的熔敷装置。该熔敷装置设有光偏转装置10，其通过电流镜等光偏转手段12使得从激光光源11射出的激光朝着任意方向偏转照射。又，该熔敷装置设有工作台13，其使得作为被熔敷物的灯体1的前面开口向着上方配置，将前面罩2载置在配置的灯体1上，再在其上配设压板14。通过该压板14，将前面罩2朝下方推压，使得前面罩2的周缘部4与灯体1的前面开口的凸缘3相接。并且，通过使得由光偏转装置10偏转控制的激光L沿着灯体1的凸缘3一边扫描一边照射，激光L透过压板14，再透过前面罩2，照射在熔敷面上，在该熔敷面中，能使得灯体1和前面罩2熔敷。在该熔敷装置中，能使得激光L相对全熔敷面高速多次照射，使得熔敷面全周同时熔敷，因此，能在短时间实现高质量熔敷。
[专利文献1]日本特开2009-56755号公报
[专利文献2]日本特开2005-254618号公报
在使用这种光偏转装置的熔敷装置中，激光由在熔敷装置内位置固定的光偏转装置10偏转控制，相对熔敷面照射，因此，因熔敷面相对光偏转装置10的相对位置不同，激光相对熔敷面的入射角变化。即，近年的车辆用灯大多根据设计要求采用朝车辆侧方回转延伸的形状，因此，前面罩和灯体的熔敷面不配置在同一平面上，在离开光偏转装置10处的熔敷面，激光的入射角变大。因此，在入射角变大处，压板14表面及前面罩2表面的激光的反射率变大，透过前面罩2照射在熔敷面的激光光量降低，所谓反射损耗成为显著。这样的入射角和反射率的关系在例如光学领域已经为人们所知，入射角从超过所定角(该所定角为接近所谓布儒斯特角的角度，根据材料的折射率而不同，在折射率为1.5前后的玻璃中，为40°～60°)左右，反射率急剧增加。因这样的反射损耗，激光在熔敷面的熔敷效率明显降低，产生熔敷时间变长且难以得到高质量熔敷的问题。尤其，在具有采用上述那样的回转延伸形状的车辆用灯的回转延伸部的灯壳体中，该回转延伸部的激光的入射角大多超过所定角，反射损耗也变得显著。
发明内容
本发明的目的在于，提供能减少偏转控制的照射光的反射损耗、实现熔敷效率高的熔敷的熔敷方法以及熔敷装置。
为了实现上述目的，本发明的熔敷方法在第一部件上使得具有光透过性的第二部件密接，从上述第二部件侧照射由光偏转装置偏转控制的光，在上述密接面熔敷两部件，其特征在于：
通过配设在上述第二部件的光照射面侧的反射率减少手段，减少照射在上述第二部件的光的反射率。
本发明的熔敷装置包括：
保持手段，使得第一部件和具有光透过性的第二部件保持为密接状态；以及
光偏转手段，对于从光源射出的光进行偏转控制，使得该光从上述第二部件侧照射在上述密接面上；其特征在于：
包括反射率减少手段，配设在上述第二部件的光照射面侧，减少上述照射光的反射率。
在此，反射率减少手段用减少照射在上述密接面的光的入射角的光学阶梯构成。或者反射率减少手段设为叠层折射率不同的透光性部件的结构。较好的是，本发明的反射率减少手段形成在用于使得上述第二部件密接在上述第一部件的推压手段上。
下面说明本发明的效果。
按照本发明，照射在熔敷面的光由反射率减少手段减少照射到第二部件期间的反射率，因此，减少照射到该第二部件的照射面时的反射损耗，能进行熔敷效率高的熔敷。
附图说明
图1是适用本发明的灯壳体一例的立体图。
图2是表示熔敷装置整体构成的概略构成图。
图3是实施形态1的压板的主要部分的放大截面图。
图4是说明实施形态1的作用的放大截面图。
图5是实施形态1的变形例1的压板的主要部分的放大截面图。
图6是实施形态1的变形例2涉及的熔敷装置的概略构成图。
图7是实施形态1的变形例2的压板的主要部分的放大截面图。
图8是实施形态2的压板的主要部分的放大截面图。
图中符号意义如下：
1     灯体
2     前面罩
3     凸缘(熔敷面)
4     周缘部(熔敷面)
10    光偏转装置
11    激光光源
12    光偏转手段(电流镜)
13    工作台
14，14A，14B   压板
141，142，143  反射率减少手段(入射角调整阶梯)
14a～14d    反射率减少手段(光透过板，光透过膜)
15    轴杆
16    导柱
具体实施方式
下面，参照附图说明本发明实施形态。在以下实施形态中，虽然对构成要素，种类，组合，形状，相对设置等作了各种限定，但是，这些仅仅是例举，本发明并不局限于此。
在本实施形态中，如图2所示，表示通过光偏转装置10偏转控制激光，熔敷作为被加工物的车辆用灯的灯体1和前面罩2的例子。即，熔敷装置的光偏转装置10设有激光光源11，从该激光光源11射出的激光由电流镜等光偏转手段12偏转控制，一边在任意的平面方向高速扫描一边照射。关于电流镜已经为人们所知，在此说明省略。又，使得进行熔敷的灯体1的前面开口向着上方固定在上述熔敷装置的工作台13上，熔敷在该灯体1的前面罩2载置在该灯体1上。上述灯体1至少进行熔敷的凸缘3的部分由具有光吸收性、通过激光加热熔融的树脂构成。较好的是，由包含例如碳等的具有光吸收性的材料的树脂构成。上述前面罩2由透过光的透明树脂构成，由通过加热时照射的光能熔融的树脂构成。并且，上述前面罩2的周缘部4的内面定位在上述灯体1的凸缘3的前面，通过配设在其上的压板14，将前面罩2相对灯体1推压，上述前面和内面密接。
[实施形态1]
将该熔敷装置作为前提，实施形态1的熔敷装置在配设在前面罩2上的压板14的局部构成反射率减少手段。该反射率减少手段具有以下功能：使得从上述光偏转装置10射出的激光L照射前面罩2外面时的入射角比上述所定角小，在此比40°小。又，该压板14与迄今为止相同还具有将前面罩2相对灯体1推压的功能，通过使得设在压板14的局部的轴杆15与没有图示的推压机构连接，当使得该推压机构动作时，压板14将前面罩2向着灯体1推压，能确保上述灯体1的凸缘3和前面罩2的周缘部4的在熔敷面的密接性，实现合适的熔敷。
图3是上述压板14的主要部分的放大截面图，是相当于设有本发明的反射率减少手段的图2A部的部分的截面图。压板14由用于熔敷的激光的光透过性高、光吸收性低的透明材料，例如丙烯树脂，PC(聚碳酸酯)树脂，玻璃(石英玻璃等)以大致均一厚度的板状部件构成。在此，为了使得以后的说明简单化，压板14相对激光的折射率设为与前面罩2的折射率相等。在上述压板14，沿着上述熔敷面R，即灯体1的凸缘3和前面罩2的周缘部4密接的区域，形成作为本实施形态1的反射率减少手段的入射角调整阶梯(step)141。该入射角调整阶梯141凹设在压板14外面，作为朝着板厚方向倾斜的斜部构成。该斜部的外面与压板14的外面相比，朝对着上述光偏转装置10的方向倾斜，由于该倾斜，入射角调整阶梯141使得从光偏转装置10射出的激光L入射到该入射角调整阶梯141时的入射角小，同时，作为使得入射激光L朝着图示下方向折射射出的阶梯构成。
因此，在设有该压板14的熔敷装置中，进行灯体1和前面罩2的熔敷时，与迄今为止相同，将灯体1配设在图2所示的熔敷装置的工作台13上，将前面罩2载置其上，用配设在前面罩2上侧的压板14推压前面罩2使其与灯体1密接。这时，当然，设在压板14的入射角调整阶梯141被定位，使其与两者的熔敷面R对向。接着，驱动光偏转装置10，用电流镜12使得来自激光光源11的激光偏转。由此，从光偏转装置10射出的激光L一边沿着熔敷面R扫描一边相对熔敷面R照射。该照射的激光L照射到压板14的入射角调整阶梯141的入射面，在该入射面折射，透过该入射角调整阶梯141射出，再入射到前面罩2的外面，透过该前面罩2，照射到与灯体1的熔敷面R，进行熔敷。
这时，如图3所示，入射角调整阶梯141的入射面对着光偏转装置10倾斜，因此，入射到该入射角调整阶梯141的激光L的入射角θ1比没有形成入射角调整阶梯141场合的入射角小。该入射角调整阶梯141呈锥形截面形状，因此，从入射角调整阶梯141的内面(背面)射出的激光L的射出角，即入射到前面罩2外面时的激光L的入射角θ2也变小。即，图4表示没有设置入射角调整阶梯时压板14的激光L的入射角，从该图4可知，向着压板14的入射角θ11比图3的入射角θ1大，向着前面罩2的入射角θ12比图3的入射角θ2大。如上所述，光入射到物质时在入射面的反射率与该入射面的光的入射角有密切关系，尤其，若入射角超过上述所定角度，则反射率急剧增加。因此，如本实施形态那样，通过使得激光因入射角调整阶梯141入射到压板14时的入射角θ1，以及入射到前面罩2时的入射角θ2分别比所定角度小，降低光入射时的反射率，减少反射损耗，能提高压板14和前面罩2的激光L的透过性。由此，提高到达灯体1和前面罩2的熔敷面R的激光L的光能量，提高熔敷效率，能实现缩短熔敷时间，以及提高熔敷质量。
根据本发明人的模拟，当将激光相对压板14入射面的入射角设为25°，熔敷面相对铅垂方向的角度设为45°时，当不存在入射角调整阶梯141的图4场合，照射到熔敷面的激光为45.8％的效率。另一方面，将图3的入射角调整阶梯141的入射面的倾斜角设为45°场合，即，压板14的该入射面向着相对铅垂方向垂直的方向，使用该压板14场合，照射到熔敷面R的激光为85.6％的效率。
在此，作为本实施形态1的变形例1，如图5所示，也可以构成为在压板14内面形成入射角调整阶梯142，作为反射率减少手段。即，在压板14的与灯体1的凸缘3和前面罩2的周缘部4对向的区域中，凹设该压板14的内面，形成斜部，构成为将该斜部作为入射角调整阶梯142的光射出面。该光射出面以大角度朝对着光偏转装置10的方向倾斜。若这样，入射到压板14的激光L入射到压板14时的入射角θ11与图4所示入射角θ11相同，但是，从入射角调整阶梯142射出时的射出角θ3向着前面罩2侧变大，因此，从入射角调整阶梯142入射到前面罩2外面时的入射角θ4比图4的入射角θ12小，减少在该前面罩2外面的反射损耗，提高熔敷面R的激光的光能量，能提高熔敷效率。在本实施形态的模拟中，当将入射角调整阶梯142的射出面倾斜角设为30°场合，照射到熔敷面R的激光为80.9％的效率。
图6是本实施形态1的不同的变形例2涉及的熔敷装置，与图2相同部分标以相同符号。在该熔敷装置中，压板14A形成作为呈平面板状的透明板，往下移动推压载置在工作台13上的灯体1和前面罩2时，构成为在相对前面罩2上面局部接触的状态下，朝下方推压。在该压板14A的周边位置，适当数量的导柱16沿着铅垂朝下方向延伸形成，当推压前面罩2时，所述导柱16成为保持所定姿势时的导向。设有光偏转装置10，通过电流镜等光偏转手段12使得从激光光源11射出的激光向着任意方向偏转照射，这与图2场合相同。
在该压板14A的内面，如在图7的图6B部放大图所示，沿着与上述灯体1和前面罩2密接的熔敷面R对向的区域，形成入射角调整阶梯143。该入射角调整阶梯143基本上与上述变形例1的入射角调整阶梯142相同，凹设该压板14A的内面，形成斜部，构成为使得该斜部作为入射角调整阶梯143的光射出面，使得该光射出面朝对着光偏转装置10的方向倾斜。若这样，与变形例1大致相同，入射到压板14A的激光L入射到压板14A时的入射角θ13比图4所示入射角θ11小，进而，从入射角调整阶梯143以射出角θ31射出，入射到前面罩2外面时的入射角θ41比图4的入射角θ12小，减少在该前面罩2外面的反射损耗，提高熔敷面R的激光的光能量，能提高熔敷效率。在该变形例2中，压板14A与前面罩2外面局部接触推压，因此，能用平面板构成压板14A，压板14A制造容易，能以低成本制造。
在上述实施形态1及其变形例1中，设在压板14的入射角调整阶梯141，142发挥使得照射到前面罩2的激光L入射到前面罩2时的入射角小的功能，该压板14可以配设在照射在前面罩2的激光L的光路上，因此，压板14并不一定要与前面罩2外面直接接触，也可以配设为相对该外面离开的状态。即，也可以构成为如变形例2那样，在前面罩2的局部或若干处局部接触推压。
[实施形态2]
图8是表示作为本发明的反射率减少手段的压板14B的实施形态2的截面图。在该实施形态2中，压板14B不设置入射角调整阶梯，而是在呈单板结构的压板14a上通过涂布等叠层折射率不同的多层透光性薄膜，以代替上述设置入射角调整阶梯。在此，将第一光透过膜14b(折射率nb)，第二光透过膜14c(折射率nc)，第三光透过膜14d(折射率nd)以密接状态叠层，使得折射率分别顺序变小(nb＞nc＞nd)。表示第一光透过膜14b的折射率nb与压板14a及前面罩2的折射率相等的例子。
在该实施形态2中，入射到压板14B的激光L的入射角θ11与实施形态1相同，但是，当激光L顺序透过第三光透过膜14d、第二光透过膜14c、第一光透过膜14b时，因在各光透过膜间的折射率的差异，入射角顺序变小，向着压板14a的入射角，即前面罩2的入射角θ5比图4的入射角θ12小。这样，在从空气到前面罩2的激光的传播路径中，通过使得折射率阶梯地变大，因在各界面的菲涅耳反射引起的反射损耗总和比不涂布薄膜场合因菲涅耳反射引起的反射损耗总和少。由此，减少照射到前面罩2时的激光L的反射率，反射损耗变少，能提高在熔敷面R的熔敷效率。
在上述实施形态中所示的各部的形状及结构都不过是实施本发明时进行的具体化一例，并不因上述实施形态限定解释本发明的技术范围。
例如，在上述实施形态中，关于本发明的熔敷方法以及熔敷装置，说明熔敷车辆前照灯的灯体和前面罩的例子，但是，也可以是用于熔敷灯单元的反射镜和前面透镜的熔敷方法以及熔敷装置，或者也可以是构成灯部件以外的熔敷方法以及熔敷装置。即，本发明只要是用于通过光照射使得第一部件和第二部件互相熔敷的熔敷方法以及熔敷装置，都能适用。尤其，对于设有光偏转装置、激光相对熔敷面不得不以大的入射角照射那样的熔敷装置，适用本发明场合很有效。
又，在本发明中，光偏转装置并不局限于设有实施形态的电流镜的光偏转装置，只要具有使得光向着任意方向偏转扫描的功能，都能适用。再有，本发明用于熔敷的光并不局限于激光，只要是具有照射时能使得第一部件和第二部件熔敷的光能量的光，都能适用。
又，在本发明中，说明将第一光透过膜14b(折射率nb)，第二光透过膜14c(折射率nc)，第三光透过膜14d(折射率nd)以密接状态叠层，使得折射率分别顺序变小(nb＞nc＞nd)，但是，本发明并不局限于此，例如，光透过膜并不局限于三层，也可以是二层，四层，或四层以上。又，折射率变化也并不局限于实施例所述顺序变小，只要能减少照射光的反射率都能适用。
又，在本发明中，说明第一光透过膜14b的折射率nb与压板14a及前面罩2的折射率相等的例子，但是，本发明并不局限于此，第一光透过膜14b的折射率nb也可以与压板14a及前面罩2的折射率不相等。
下面，说明在产业上的可利用性。
本发明在使得第一部件和第二部件密接、透过第二部件使得光照射在密接面上、将该密接面作为熔敷面熔敷二个部件的熔敷方法以及熔敷装置中，可以采用。

Claims (3)

1.一种熔敷方法，在第一部件上使得具有光透过性的第二部件密接,从上述第二部件侧照射由光偏转装置偏转控制的光,在上述密接面熔敷两部件,其特征在于:
通过配设在上述第二部件的光照射面侧的反射率减少手段,减少照射在上述第二部件的光的反射率；
上述反射率减少手段为减少照射在上述密接面的光的入射角的光学阶梯。
2.一种熔敷装置，包括:
保持手段,使得第一部件和具有光透过性的第二部件保持为密接状态；以及
光偏转手段,对于从光源射出的光进行偏转控制,使得该光从上述第二部件侧照射在上述密接面上；其特征在于:
包括反射率减少手段,配设在上述第二部件的光照射面侧,减少上述照射光的反射率；
上述反射率减少手段为减少照射在上述密接面的光的入射角的光学阶梯。
3.根据权利要求2记载的熔敷装置,其特征在于:
上述反射率减少手段形成在用于使得上述第二部件密接在上述第一部件的推压手段上。
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