CN104608374A - 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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CN104608374A
CN104608374A CN201410449834.0A CN201410449834A CN104608374A CN 104608374 A CN104608374 A CN 104608374A CN 201410449834 A CN201410449834 A CN 201410449834A CN 104608374 A CN104608374 A CN 104608374A
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deposition
light
component
recessed region
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CN104608374B (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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    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
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    • F21S41/28—Cover glass
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    • 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

本发明涉及熔敷结构以及熔敷装置。本发明的熔敷结构在第一部件即灯体(1)上使得具有光透过性的第二部件即前面罩(2)密接,从第二部件(2)侧投射点光即激光(L),在该密接面即熔敷面(11a、21a)熔敷第一部件(1)和第二部件(2),在该点光(L)投射的第二部件(2)的表面存在的凹区域(22)的曲率半径(R)为熔敷部(X)的宽度尺寸(Wx)的2倍以上。该熔敷部(X)的宽度尺寸(Wx)与点光(L)的点径(r)大致相等,因此,曲率半径(R)成为点径(r)的2倍以上。提供提高利用激光等的光的熔敷的熔敷质量的熔敷结构以及熔敷装置。

Description

熔敷方法以及熔敷装置
技术领域
本发明涉及照射激光等光熔敷被加工物的熔敷结构以及用于实现该熔敷结构的熔敷装置。
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,作为进行该固接的技术,使用熔敷灯体和前面罩的技术。即,为以下方法:使得透明的前面罩与灯体抵接,相对该抵接面从前面罩侧投射激光,因该激光的光能量在抵接面使得两者熔融且接合的方法。又,为了提高由该熔敷方法所得到的熔敷质量,还存在以下技术:将呈透明板状的透明夹具配设在前面罩侧,由该透明夹具将前面罩推压在灯体上,在提高两者的抵接面的密接性的状态下进行熔敷。
但是,若使用这样的透明夹具进行激光熔敷,当投射在熔敷部的激光透过透明夹具以及前面罩时,有时点径增大,产生熔敷质量降低问题。即,投射激光在透明夹具或前面罩的表面发生折射,因该折射,熔敷面中的激光的点径增大。若点径增大,则激光的每单位面积的光能量(以下,称为“光能量密度”)降低,熔敷质量降低。在专利文献1中,提出为了防止因透明夹具和前面罩的合计厚度尺寸差异引起激光的点径变化,使得该合计厚度尺寸相等的技术。
[专利文献1]日本特开2006-12502号公报
根据专利文献1的技术，点径保持均一在改善熔敷质量方面有效。但是,根据本发明人研究得知，在从激光投射方向看熔敷面凹形状的部位，难以使得激光的点径保持均一。即，详细在后文说明，如图6(a)、(b)所示，当在灯体1的熔敷面11a的局部存在截面为角形状或曲率半径尺寸小的凹区域12时，若将前面罩2载置在该熔敷面11a上，再将透明夹具3载置其上，投射激光L，进行激光熔敷，则从透明夹具3的表面向着熔敷面11a入射的激光在与熔敷面11a的凹区域12对应、形成在透明夹具3的表面的凹区域32中，向着两外侧方向折射，熔敷面11a中的激光L的点径在沿着凹区域12的方向增大。因此，在该凹区域12的熔敷面11a中的激光L的光能密度降低，熔敷质量降低。为了防止该透明夹具3的凹区域32的点径增大，考虑将透明夹具3的表面形成为平坦面，但是，这样，该凹区域中的透明夹具的厚度尺寸变大，产生因包含专利文献1记载的透明夹具的厚度尺寸偏差引起点径变化问题。
发明内容
本发明的目的在于，提供提高由激光等进行熔敷的熔敷质量的熔敷结构以及熔敷装置。
为了实现上述目的,本发明的熔敷结构在第一部件上使得具有光透过性的第二部件密接,从上述第二部件侧投射点光,在上述密接面熔敷两部件,其特征在于:
在上述点光投射的上述第二部件的表面存在的凹区域的曲率半径为熔敷部的宽度尺寸的2倍以上。
上述“2倍以上”包括2倍。
在该熔敷结构中,例如,上述第一部件是灯具的灯体,上述第二部件是透光性罩,上述灯体的开口缘部和上述透光性罩的周缘部熔敷,在上述开口缘部和周缘部的至少局部形成上述凹区域,上述熔敷部沿着上述开口缘部和上述周缘部的长度方向延伸,上述凹区域的曲率半径为该熔敷部的与长度方向正交的宽度尺寸的2倍以上。
本发明的熔敷装置包括:
保持手段(机构),将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
光投射手段(机构),使得从光源射出的点光透过上述保持手段,从上述第二部件侧投射到与上述第一部件的密接的面,其特征在于:
在上述保持手段的上述点光入射的表面存在的凹区域的曲率半径为上述点光的点径的2倍以上。
在该熔敷装置中,较好的是,上述保持手段作为具有透光性的透明夹具构成,相对上述第一部件推压上述第二部件,该透明夹具的上述凹区域具有与形成在上述第二部件的凹区域相同的曲率半径。
下面说明本发明的效果:
本发明的熔敷装置的保持手段密接保持第一部件和第二部件,在为了熔敷的点光入射的面形成的凹区域的曲率半径为该点光的点径的2倍以上,因此,透过第二部件投射在熔敷面的点光的点径或点面积不会无益地增大,能将用于进行熔敷的光能密度的降低率保持在所设定的水平,能制造高熔敷质量的熔敷结构。又,用该熔敷装置能实现本发明的熔敷结构,本发明的熔敷结构通过光能密度的降低率低的点光形成熔敷部,因此,能得到高的熔敷质量。再有,根据本发明的熔敷结构,能以均一厚度形成本发明的保持手段,能防止因厚度差异引起光能密度的降低。
附图说明
图1是适用本发明的汽车尾灯的外观立体图及其局部的分解立体图。
图2(a)、(b)是用于说明灯体和前面罩、透明夹具的各凹区域的放大图。
图3是激光熔敷装置的概念构成图。
图4(a)、(b)是说明实施形态的在凹区域的激光点径的平面图和纵截面图。
图5表示凹区域的曲率半径和光能密度降低率的关系。
图6(a)、(b)是说明在曲率半径小的凹区域的激光点径的平面图和纵截面图。
图中符号意义如下:
1   灯体(第一部件)
2   前面罩(第二部件)
3   透明夹具(保持手段)
11  开口缘部
21  周缘部
12,22,32  凹区域
12b,22b,32b  底部
11a,21a  熔敷面
100 激光熔敷装置
101 激光投射装置
102 熔敷台
L   激光(点光)
r   点径
X   熔敷部
Wx  熔敷部X的宽度尺寸
R   凹区域(底部)的曲率半径
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,作为本发明的熔敷结构，如图1所示,表示将本发明适用于根据外观上要求在灯前面局部存在凹区域的汽车左侧尾灯TL的例子。图1是该尾灯TL的全体构成的概略立体图，在图1下侧表示其局部的分解立体图。该尾灯TL的灯体1是本发明的第一部件，其将具有光吸收性的树脂成形为容器状，其开口缘部11的前面作为熔敷面11a构成。
上述尾灯TL的前面罩2是本发明的第二部件，其将具有光透过性的树脂成形，以具有沿着上述灯体1的开口缘部11的轮廓的外形,形成为具有大致均一厚度的板状。该前面罩2的周缘部21的内面作为熔敷面21a,与上述灯体1的开口缘部11的前面、即熔敷面11a密接,在该熔敷面21a中,熔敷上述灯体1的熔敷面11a。以上述灯体1和前面罩2构成尾灯的灯壳体,光源及光学部件内装在该灯壳体,构成上述尾灯TL,在此,其具体构成说明省略。
在上述灯体1,根据汽车的车体外观要求,在上述开口缘部11的多处,向着灯体1的底方向,形成大致凹为V字状的凹区域12。在此,在上述开口缘部11的左右缘部,形成在上下方向配设为二段的凹区域12。又,在上述前面罩2,也在从表面看时与上述灯体1的凹区域12对应的部位,形成朝左右方向延伸的上下二段的槽状的凹区域22。并且,在包含上述凹区域12及22的上述灯体1的熔敷面11a和上述前面罩2的熔敷面21a,沿着上述熔敷面11a、21a全长,形成呈现所需要的宽度尺寸Wx的熔敷部X,通过该熔敷部X,如上所述,熔敷灯体1和前面罩2。
图2(a)是使得上述灯体1的开口缘部11向着上方状态的上述凹区域12、22的放大图。在该实施形态中,如上所述,开口缘部11的凹区域12在沿着开口缘部11的长度方向的二维方向形成为大致V字状,因此,左右夹着凹区域12的最凹的底部12b的两侧的倾斜面(以下,称为“倾斜面”)12l、12r朝着以所需要的角度交叉的方向延长形成,以便构成V字形状。并且,在由该两侧的倾斜面12l、12r夹住的底部12b,其表面形成为上述熔敷部X的宽度尺寸Wx的二倍以上的曲率半径R的曲面。
又,在上述前面罩2形成的凹区域22也与灯体1的上述凹区域12相同,由左右倾斜面22l、22r和底部22b形成,尤其,其底部22b形成为与灯体1的凹区域12相同曲率半径R的曲面,即,形成为上述熔敷部X的宽度尺寸Wx的二倍以上的曲率半径R的曲面。关于这样使得灯体1和前面罩2的凹区域12、22的底部12b、22b的曲率半径R形成为熔敷部X的宽度尺寸Wx的二倍以上的理由,将在后文说明。
图3是将上述前面罩2熔敷在上述灯体1的激光熔敷装置100的概念构成图。在激光熔敷装置100的上侧位置配设激光投射装置101。该激光投射装置101为以下装置:从没有图示的激光光源发出激光,通过聚光光学系统作为所设定的光束直径的激光L、即所设定的点径的激光射出,且通过没有图示的偏转光学系统向着任意方向一边扫描一边投射。例如,作为偏转手段,可以使用电流镜装置。或者也可以构成为通过控制激光装置全体朝任意方向移动,进行扫描。
在上述激光投射装置101的下方位置,在上述激光L投射区域,配设熔敷台102,在该熔敷台102上,上述灯体1使得开口缘部11向着上方被支持。在该灯体1上,载置上述前面罩2,其周缘部21与该灯体1的开口缘部11重叠。这时,不用说,上述灯体1的熔敷面11a和前面罩2的熔敷面21a重叠为密接状态。进而,将透明夹具3载置在该前面罩2上，由没有图示的支持机构以推压前面罩2的状态抵接。由此，上述灯体1的熔敷面和上述前面罩2的熔敷面互相抵接为密接状态。该透明夹具3作为保持手段构成,用于将本发明的第一部件和具有光透过性的第二部件保持为密接状态。
上述透明夹具3用具有光透过性的树脂、在此为透明的丙烯树脂形成。图2(b)是与图2(a)对应部位的放大图,该透明夹具3与专利文献1记载的技术相同,基本上设计为从与前面罩2抵接的背面起算的厚度尺寸成为均一。因此,与分别形成在上述灯体1的开口缘部11和上述前面罩2的周缘部21的凹区域12、22对应的区域,也形成呈同样的表面形状的凹区域32。该凹区域32由倾斜面32l、32r和底部32b构成,所述倾斜面32l、32r以与上述灯体1和前面罩2的各凹区域12、22的左右倾斜面相同角度倾斜,所述底部32b由上述倾斜面32l、32r夹着,该底部32b的表面形成为与上述灯体1和前面罩2的各凹区域12、22的曲率半径R相同曲率半径R的曲面。
在上述激光熔敷装置100中,当将前面罩2熔敷在灯体1时,如图3所示那样,将灯体1支持在熔敷台102上,在其上载置前面罩2,再将透明夹具3载置其上，通过由支持机构推压透明夹具3,透明夹具3将前面罩2朝下方推压,使得前面罩2的熔敷面与灯体1的熔敷面抵接为密接状态。在此基础上,从激光投射装置101向着与熔敷面对应的区域投射所需要的点径的激光L。
投射的点状的激光L(以下,称为“点光”)透过透明夹具3,再透过位于其下侧的前面罩2的周缘部21,投射到与灯体1的开口缘部11密接的熔敷面21a、11a。透明夹具3和前面罩2为具有光透过性的树脂,但是,由于灯体1用具有光吸收性的树脂形成,因此,因投射的点光L,灯体1吸收光而发热,因该发热,进行前面罩2的熔敷。点光L沿着熔敷面扫描,因此,涉及熔敷面全长,前面罩2熔敷在灯体1。在该熔敷中,一边点光L进行扫描一边进行熔敷,因此,如图1所示那样,上述熔敷部X成为以与该点光L的点径对应的宽度尺寸Wx、沿着密接面延长的线状区域。
图4(a)、(b)是用于说明点光L投射在透明夹具3表面时状态的平面图和纵截面图。相对透明夹具3、前面罩2的厚度尺寸,从激光投射装置101到熔敷台102的距离充分大,因此,从激光投射装置101投射的上述点光L看作从相对透明夹具3的表面大致垂直方向投射。又,透明夹具3的除凹区域32的区域基本上呈接近均一厚度尺寸的平面的形状,因此,投射到透明夹具3的表面、入射到透明夹具3、透过该透明夹具3以及前面罩2的点光L几乎没有折射地投射到熔敷面,实行激光熔敷。这时,当点光L投射到透明夹具3的表面且扫描时,图4(a)用点划线表示的区域设为熔敷部X,该熔敷部X的与扫描方向垂直方向的宽度尺寸Wx成为熔敷部X的宽度尺寸,该宽度尺寸Wx与点光L的点径r相等。
另一方面,当点光L投射到透明夹具3的凹区域32时,凹区域32的左右的倾斜面32l、32r相对与点光L的入射方向垂直的面倾斜,因此,若在例如图4(a)、(b)中,从凹区域32的左侧向着右侧,点光L扫描,则由于透明夹具3的折射率比空气的折射率大,折射角比入射角小,因此,投射到凹区域32的左侧的倾斜面32l的光朝左方向折射,在右侧的倾斜面32r朝右方向折射。并且,当点光L投射到底部32b时,该点光在底部32b的曲面折射,因此,点光L的点径在沿着扫描的方向增大,其长轴成为r1(r1＞r)。
即,底部32b是凹曲面,因此,与光在凹透镜的折射相同,透过透明夹具3和前面罩2的点光L的点径r在扫描方向增大,如图4(a)那样,投射到底部32b的点光L在熔敷面11a、21a成为具有在扫描方向长的长轴r1的长圆形状。因此,在熔敷面中成为长圆形状的点光L的点面积比圆形场合增大。若点面积这样增大,则其光能密度降低,熔敷面中的熔融不充分,担心熔敷质量降低,或成为不能熔敷。
为了验证,本发明人使得透明夹具3的凹区域32的表面的曲率半径R不同,相对该透明夹具3,投射点光L时,熔敷面中的点面积的变化,换言之,光能密度变化,图5表示检测该变化的试验结果。在此,使用对于图2(b)所示透明夹具3和前面罩2,光折射率1.5左右丙烯树脂,将透明夹具3的厚度尺寸设为8mm,前面罩2的周缘部21的厚度尺寸设为2mm。又,在凹区域32的左右倾斜面32l、32r相对水平方向形成的角度设为50°。并且,由图3所示激光熔敷装置100向透明夹具3的表面投射点径3mm的点光,透过透明夹具3和前面罩2,投射在熔敷面,进行熔敷。
在图5中,横轴表示凹区域32的曲率半径R,在此,表示点光L的点径r的多少倍。例如,R＝2r表示曲率半径R是点径r的2倍,点径为3mm,因此,曲率半径R成为6mm。纵轴如该图上侧所记载那样,表示将点光L投射在平面时的点径r的点面积作为基准,将点光L投射在凹区域时的点面积增大引起的光能密度的降低率。
并且,在图5中,在检测的多个值之中,表示将曲率半径R设为0.5r、1r、2r、3r时的光能密度的降低率(点表示)。在各点表示位置中,表示各自的光能密度降低率以及此时的点面积的具体值。根据图5可知,得到以下相关关系:若凹区域32的曲率半径R小,则光能密度的降低率大,若曲率半径R变大,则光能密度的降低率降低。
另一方面,根据本发明人的试验,得到确认,当进行该熔敷时,若光能密度的降低率为30～40％程度以下,则能熔敷,若光能密度的降低率比其大,则熔敷不充分。于是,在本发明中,为了实现可靠性高的熔敷,设定曲率半径R,使其成为35％以下的降低率。根据图5结果,光能密度的降低率成为35％是曲率半径R为2r附近。因此,可知若将曲率半径R设为2r以上,换言之,若将曲率半径R设为点径r的2倍以上,则能使得光能密度的降低率成为35％以下,能实现高质量的熔敷。
于是,在本实施形态中,透明夹具3的凹区域32的底部32b的表面的曲率半径R形成为点光L的点径r的2倍。换言之,如图4(a)所示,点光L的点径r与熔敷部X的宽度尺寸Wx大致相等,因此,也可以说凹区域32的底部32b的曲率半径R形成为熔敷部X的宽度尺寸Wx的2倍。
若参照图4(b),透明夹具3的凹区域32的底部32b的表面的曲率半径R形成为点光L的点径r的2倍以上,因此,点光L入射的透明夹具3的凹区域32的底部32b的表面,与其两侧的倾斜面32l、32r的表面相比,相对激光L投射方向的角度变小。由此,投射的点光L投射到底部32b的表面时的入射角变小,点光L朝左右折射的角度变小,点径(长轴尺寸)成为r1。
与此相反,图6(a)、(b)是透明夹具3的凹区域32的底部32b为角形状或曲率半径R形成为比点径r的2倍小场合的平面图和纵截面图。在该场合,若参照图6(b),点光L入射到底部32b的透明夹具3的表面,与其两侧的倾斜面32l、32r的表面大致角度相同,因此,投射到底部32b的点光L发生与在左右倾斜面32l、32r的折射同样的折射。因此,点光L向着左右两方向发生大折射,该点光L的点径(长轴尺寸)成为r2。
若比较图4和图6的点光L的点径r1、r2,则透明夹具3的凹区域32的底部32b的表面倾斜小的图4的点径r1明显比图6的点径r2小。如上所述,在图4所示实施形态的点径r1场合,点光L的点面积小,光能密度的降低率为35％以下,因此,熔敷质量得到改善。与此相反,在图6的点径r2场合,点面积变大,光能密度的降低率比35％～40％大,因此,熔敷质量降低。
这样,通过将透明夹具3的凹区域32的底部32b的曲率半径R设为激光L的点径r的2倍以上,能抑制在透明夹具3的表面折射的点光L的点径增大,即,能抑制点面积增大,抑制光能密度的降低率,能提高熔敷质量。换言之,通过将凹区域32的底部32b的曲率半径R设为与激光L的点径r具有密切关系的熔敷部X的宽度尺寸Wx的2倍以上,能抑制光能密度的降低率,能实现高质量的熔敷。
在本实施形态中,将作为保持手段的透明夹具3形成为均一厚度,因此,透明夹具3的凹区域32的曲率半径R与前面罩2的凹区域22的表面的曲率半径相等。即,在本发明的熔敷结构中,当使用均一厚度的透明夹具3,进行第一部件和第二部件的熔敷场合,可以将作为第二部件的前面罩2的凹区域22的底部22b的表面的曲率半径R形成为熔敷部X的宽度尺寸Wx的2倍以上。因此,与厚度不均一的透明夹具3比较,还能实现熔敷部的熔敷质量均一化。
又,透明夹具3不一定非要均一厚度,只要对熔敷不带来坏影响程度,也可以使得凹区域32厚度多少厚些。这种场合,若透明夹具3的凹区域32的曲率半径R形成为点径r的2倍以上,则前面罩2的凹区域22的曲率半径R也可以不一定是点径r的2倍以上。这是由于点光L的折射在透明夹具3的表面进行,因此,在该表面的折射成为决定熔敷面的点径、即点面积或光能密度的降低率的要素的缘故。
在本实施形态中,说明凹区域沿着灯体的开口缘部和前面罩的周缘部进行在二维的凹区域的熔敷,但是,即使如圆锥凹部状那样在三维方向凹下构成的凹区域,至少关于激光扫描的方向,也能同样适用本发明。
本发明是使得激光等的光透过透明夹具投射到熔敷面、使得该熔敷面熔敷的熔敷结构,只要沿着使得用于进行熔敷的光扫描的方向存在凹区域的熔敷结构,并不限定为本实施形态的灯壳体的熔敷结构。又,本发明的熔敷装置并不限定为制造汽车的灯壳体时的熔敷装置。
下面,说明在产业上的可利用性。
本发明在使得激光等的光透过透明夹具投射到熔敷面、使得该熔敷面熔敷的熔敷结构以及用于实现该熔敷结构的熔敷装置中,可以采用。

Claims (4)

1.一种熔敷结构，在第一部件上使得具有光透过性的第二部件密接,从上述第二部件侧投射点光,在上述密接面熔敷两部件,其特征在于:
在上述点光投射的上述第二部件的表面存在的凹区域的曲率半径为熔敷部的宽度尺寸的2倍以上。
2.根据权利要求1记载的熔敷结构,其特征在于:
上述第一部件是灯具的灯体,上述第二部件是透光性罩,上述灯体的开口缘部和上述透光性罩的周缘部熔敷,在上述开口缘部和周缘部的至少局部形成上述凹区域,上述熔敷部沿着上述开口缘部和上述周缘部的长度方向延伸,上述凹区域的曲率半径为该熔敷部的与长度方向正交的宽度尺寸的2倍以上。
3.一种熔敷装置，包括:
保持机构,将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
光投射机构,使得从光源射出的点光透过上述保持机构,从上述第二部件侧投射到与上述第一部件的密接的面,其特征在于:
在上述保持机构的上述点光入射的表面存在的凹区域的曲率半径为上述点光的点径的2倍以上。
4.根据权利要求3记载的熔敷装置,其特征在于:
上述保持机构作为具有透光性的透明夹具构成,相对上述第一部件推压上述第二部件,该透明夹具的上述凹区域具有与形成在上述第二部件的凹区域相同的曲率半径。
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