CN1088171C - 车灯及其振动式熔接方法 - Google Patents

车灯及其振动式熔接方法 Download PDF

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Publication number
CN1088171C
CN1088171C CN97110031A CN97110031A CN1088171C CN 1088171 C CN1088171 C CN 1088171C CN 97110031 A CN97110031 A CN 97110031A CN 97110031 A CN97110031 A CN 97110031A CN 1088171 C CN1088171 C CN 1088171C
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China
Prior art keywords
glass
lamp body
car light
leg
flange
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Expired - Fee Related
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CN97110031A
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English (en)
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CN1167895A (zh
Inventor
杉山富士彦
曾我茂行
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Koito Manufacturing Co Ltd
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Koito Manufacturing Co Ltd
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Priority claimed from JP7313296A external-priority patent/JP3272939B2/ja
Priority claimed from JP8087575A external-priority patent/JPH09259607A/ja
Application filed by Koito Manufacturing Co Ltd filed Critical Koito Manufacturing Co Ltd
Publication of CN1167895A publication Critical patent/CN1167895A/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/302—Particular design of joint configurations the area to be joined comprising melt initiators
    • B29C66/3022—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined
    • B29C66/30223—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined said melt initiators being rib-like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B29C65/0609—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding characterised by the movement of the parts to be joined
    • B29C65/0618—Linear
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B29C65/069—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding the welding tool cooperating with specially formed features of at least one of the parts to be joined, e.g. cooperating with holes or ribs of at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
    • B29C65/782—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined
    • B29C65/7823—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint
    • B29C65/7829—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint said distance pieces being integral with at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/05—Particular design of joint configurations
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    • B29C66/114—Single butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/301—Three-dimensional joints, i.e. the joined area being substantially non-flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/305—Decorative or coloured joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/342—Preventing air-inclusions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/542—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining hollow covers or hollow bottoms to open ends of container bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73115—Melting point
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73115—Melting point
    • B29C66/73116—Melting point of different melting point, i.e. the melting point of one of the parts to be joined being different from the melting point of the other part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/733—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
    • B29C66/7332—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being coloured
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    • B29C66/73322—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being coloured both parts to be joined being coloured both parts to be joined having a different colour
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B29C66/733—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
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    • B29C66/73365—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light at least one of the parts to be joined being transparent or translucent to visible light
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/832—Reciprocating joining or pressing tools
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
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Abstract

一种车灯，包括：一个由合成树脂制成并具有一开口的灯体；一个从灯体开口的圆周部分侧向伸出且具有一连接表面的凸缘；一块由合成树脂制成的前玻璃；和一个在前玻璃的后表面的圆周部分上形成的焊脚，其中，前玻璃以下述方式熔接到灯体上，即前玻璃的焊脚端部嵌入到灯体凸缘的连接表面中，从而在凸缘的连接表面和前玻璃的焊脚之间形成嵌入型熔接接头。

Description

车灯及其振动式熔接方法
本发明涉及一种车灯，其中灯体的连接部分直接熔接在用于盖在灯体开口上灯玻璃的连接部分上，所述的灯体用于形成诸如汽车信号灯等车灯，本发明尤其涉及一种车灯及其振动式熔接方法，其中两元件的连接部分借助于摩擦热部分地熔化并随后冷却以熔接在一起，所述摩擦热由电磁振动产生。
将热塑合成树脂制成的灯体的连接部分直接熔接到热塑合成树脂制成的前玻璃上可形成一种车灯。即，通过所谓的“热板式熔接方法”可形成一种车灯。一般依据这种方法形成的车灯51可如图11所示。从图11中可以看出，车灯51的优点在于灯体52和前玻璃3的熔接部分54，即元件熔接在一起的地方厚度很小，因此在有限的灯体空间内，其有效面积足够大。热板式熔接方法以下述方式进行：在工件的熔接部分54之间夹持一块高温金属板，上述工件即为欲熔接在一起的灯体52和前玻璃53。即工件的熔接部分(即灯体52的焊脚52a和前玻璃53的焊脚53a)通过加热金属板而热变形或受热熔化，使得它们熔接在一起而形成车灯。
但是，用热板式熔接方法形成的车灯51具有如下缺点：如图12所示，在熔接接头54处易形成气泡C、C…，所述接头54是由将灯体52的焊脚52a与前玻璃的焊脚53a熔接在一起而形成的。另外，由于熔接接头54相对较大，因此它影响了车灯的外观。而且，由于该熔接接头是通过将灯体52和前玻璃53的焊脚52a和53a的端部熔接而形成的，所以熔接接头54不仅熔接强度低而且很脆。在车灯的制造过程中，使用加热的金属板会提高环境温度，这就使工作环境条件恶化并对周边设备的运作产生负面影响。
依据热板式熔接方法成形的车灯还存在如下不足：如图11所示，当汽车在雨天行驶时，打在前玻璃53上的水滴会经过灯体52的侧壁而流到灯体后壁上，并通过通气孔55进入灯室56，或者淋湿车灯的电气系统，结果会产生故障。
由于上述原因，本发明的目的是提供一种车灯及其振动式熔接方法，其中，将诸如灯体和玻璃等工件相连时，在上述工件之间产生足够的摩擦热，以使工件的熔接部分能完全热变形或熔化，从而将工件牢固地熔接在一起。
本发明的另一目的是提供一种车灯，它可避免上述不足，即避免打在前玻璃上的水滴通过通气孔而进入灯室，或淋湿车灯的电气系统。
依据本发明的第一方面，提供一种车灯，它包括：一个由合成树脂制成并且具有第一连接部分的第一元件；和一个由合成树脂制成并且具有第二连接部分的第二元件，其中第一元件的第一连接部分以下述方式熔接到第二元件的第二连接部分上，即第一和第二连接部分之一嵌入到另一连接部分中。
依据本发明的第二方面，提供一种车灯，它包括：一个由合成树脂制成并具有一开口的灯体；一个从灯体开口的圆周部分侧向伸出且具有一连接表面的凸缘；一块由合成树脂制成的前玻璃；和一个在前玻璃的后表面的圆周部分上形成的焊脚，其中，前玻璃以下述方式熔接到灯体上，即前玻璃的焊脚端部嵌入到灯体凸缘的连接表面中，从而在凸缘的连接表面和前玻璃的焊脚之间形成嵌入型熔接接头。
依据本发明的第三方面，提供一种车灯，它包括：一块由合成树脂制成并具有一开口的第一玻璃；一个从第一玻璃开口的圆周部分侧向伸出并具有一连接表面的凸缘；一块由合成树脂制成的第二玻璃；和一个在第二玻璃后表面的圆周部分上形成的焊脚，其中，第二玻璃以下述方式熔接到第一玻璃上，即第二玻璃的焊脚端部嵌入到第一玻璃凸缘的连接表面中，从而在凸缘连接表面和第二玻璃的焊脚之间形成嵌入型熔接接头。
依据本发明的第四方面，提供一种依据本发明第三方面的车灯，其中第一和第二玻璃是颜色互不相同的彩色玻璃。
依据本发明的第五方面，提供一种车灯振动式熔接方法，它包括以下步骤：(a)将具有一连接部分的第一工件装配到下部接收夹具中且使连接部分面朝上；(b)固定第一工件以使连接部分不在振动方向上共振；(c)将具有一连接部分的第二工件置于第一工件上，且使第二工件的连接部分与第一工件的连接部分的上表面相邻接；(d)向上移动下部接收夹具，直到第一工件以预定压力抵压在下部接收夹具的下表面上，所述下部接收夹具牢固地固定在一振动发生装置的下端；和(e)与预定压力施加方向垂直的方向上振动上部接收夹具，以便在第一和第二工件的接触区域上产生摩擦热，从而将第一和第二工件的连接部分熔接在一起。
依据本发明的第六方面，提供一种依据本发明第五方面的方法，其中，第一工件是一块带有焊脚的玻璃，而第二工件是一个带有凸缘的灯体，灯体开口的圆周部分牢固地置于下部接收夹具上并被紧固，以使开口的圆周部分不会在振动方向上共振，玻璃的焊脚端部紧靠在灯体凸缘的上表面上，此后，下部接收夹具向上移动，直到玻璃表面被推压到上部接收夹具的下表面上，以向灯体推压的上表面和玻璃焊脚的接触区域施加以一预定压力，所述上部接收夹具固定在振动发生装置的下端，在这种状态下，上部接收夹具在与所述预定施加方向垂直的方向上振动。
依据本发明的第七方面，提供一种依据本发明第五方面的方法，其中，第一工件是一块第一玻璃，而第二工件是一块与第一玻璃颜色不同的第二玻璃。
依据本发明的第八方面，提供一种依据本发明第六方面的方法，其中，沿作为第一工件的灯体凸缘的外圆周成形的排水肋牢固地安装在下部接收夹具中成形的一个安装槽内，从而当上部接收夹具振动时，防止了灯体开口的圆周部分的共振。
依据本发明的第九方面，提供了一种车灯，它包括：一个由合成树脂制成并且具有一开口的灯体；一个从灯体开口的圆周部分侧向伸出且具有一连接表面的凸缘；一个由合成树脂制成的前玻璃；一个在前玻璃的后表面的圆周部分上形成的焊脚；和一个从灯体凸缘的外圆周部分延伸的排水肋，该排水肋向灯体后壁弯折。
依据本发明的第十方面，提供一种依据本发明第九方面的车灯，其中，排水肋的端部截面呈锐角形式。
依据本发明的第十一方面，提供一种依据本发明第九方面或第十方面之一的车灯，其中，排水肋仅成形于车灯的下部。
在本发明的车灯中，形成车灯并均由合成树脂制成的第一和第二元件以下述方式相互熔接，即第二元件的连接部分的端部嵌入到第一元件的连接部分中，以使第一和第二元件的连接部分牢固地熔接在一起，即前玻璃牢固地熔接在灯体上。另外，玻璃连接部分的体积被减小，即颜色不同的两块玻璃的连接部分制得很小。
在本发明的振动式熔接方法中，由于向灯体和玻璃(工件)的连接部分施加了适当压力，所以玻璃的振动就会使局部产生摩擦热。因此，开口的圆周部分(焊脚端部)会切入灯体或另一玻璃的开口的圆周部分(凸缘的上表面)中，所述灯体或另一玻璃是在固定侧受热变形或熔化的工件，即，前者和后者的连接部分以下述方式熔接在一起，即前者的连接部分嵌入到后者的连接部分中去。
本发明的熔接方法可用于制造灯体很深的车灯。即，在该方法中，排水肋装配于下部接收夹具的槽中，以使灯体侧壁可不随玻璃的振动而共振。因此，当玻璃振动时，灯体开口的圆周部分被完全牢固地夹持住，从而产生足够的摩擦热，即工件的连接部分被可靠地熔接在一起。
依据这种设计形成的车灯，通过弯折灯体凸缘的外部圆周部分而形成的排水肋可抖落水滴，否则，当汽车在雨天行驶时，这些水滴会经过灯体侧壁流到灯体后壁上，即排水肋能防止水滴通过灯体后壁上形成的通气孔而流入灯室，或淋湿车灯的电气系统。
特别是，在车灯排水肋从灯体向后伸出的情况下，排水肋的性能得以改善，即当汽车在雨天行驶时，排水肋可抖落打在前玻璃3上并从灯体2的侧壁流到后壁的水滴。
在取代两条通气孔而只在灯体后壁的下部上制有一条通气孔的情况下，排水肋可仅成形于灯体凸缘的下部上以防止水滴进入通气孔中。
图1表示车灯的一个实例，它构成了本发明的第一实施例。特别是，图1是灯体周围带有排水肋的车灯的剖视图；
图2表示依据本发明车灯的另一实例，其中仅在灯体的下壁上形成有排水肋；
图3、图4和图5均为放大剖视图，表示灯体开口的圆周部分和前玻璃开口的圆周部分的连接区域的一个实例；
图6表示车灯的另一实例，它构成本发明的第二实施例。特别是，图6表示一种双色玻璃的立体图，该双色玻璃是通过将颜色互不相同的第一和第二玻璃的边缘熔接在一起而形成的；
图7表示颜色不同的第一和第二玻璃的连接区域的剖视图；
图8是为了说明熔接装置的原理解释性示意图，该熔接装置采用依据本发明所述的振动式熔接方法；
图9表示熔接装置中的上部接收夹具和下部接收夹具的放大剖视图；
图10(a)和图10(b)表示前玻璃焊脚的另一实例的剖视图。特别是，在图10(a)中，焊脚端部大致成锥形，而在图10(b)中，焊脚端部大致成半球形；
图11表示依据热板式熔接方法形成的传统车灯的侧剖视图；以及
图12表示灯体与前玻璃的连接部分的放大剖视图，上述灯体与前玻璃的连接是依据热板式熔接方法熔接在一起的。
下面将参照附图对本发明的最佳实施例加以说明。
图1表示车灯的一个实例，它构成了本发明的第一实施例。
根据本发明所述的车灯1是将焊脚(或连接部分)3a的前端与一凸缘(或连接部分)2a直接熔接起来而形成的，所述焊脚3a形成于一热塑合成树脂制成的前玻璃(或元件)3的后表面圆周上，所述凸缘2a从一灯体(或元件)2的开口边缘沿径向向外延伸，该灯体2也由热塑合成树脂制成。灯体2和前玻璃3的熔接接头4的厚度很小，因此在有限的灯体空间内，其有效面积足够大。通气孔6和6从灯体2的后部向后延伸，以将灯室5的内部和外部互相连通，从而防止灯体室5存有湿气而模糊不清。
一条排水肋7从灯体2的凸缘2a的外部边缘向后延伸。该排水肋7有如下作用：即，当汽车在雨天行驶时，排水肋7可以抖落水滴，否则，水滴会打在前玻璃上，并经过灯体的侧壁流到后壁而进入灯室5。为了改进排水肋的功用，最好是排水肋7的端部截面呈锐角形状。
依据灯的结构，如图2所示，排水肋7可仅形成于灯体2的凸缘2a的下部边缘上。在车灯1呈下述形式的情况下，即灯体2较大且其开口边缘向后弯折时，击打在前玻璃上的水滴将无法流入通气孔6。在这种形式的车灯中，不必在车灯1的上壁上成形排水肋7。
图3至图5表示依据本发明所述车灯的熔接部分。
在本发明的车灯1中，前玻璃3的外圆周上形成的焊脚3a的端部嵌入灯体2的上表面2a中。特别是，焊脚3a的端部被凸缘2a的熔化材料所包围，使得焊脚和凸缘牢固地连接在一起。为了将焊脚3a的端部嵌入凸缘2a的上表面中，采用了一种振动式熔接方法(将在后文描述)。
在上述实施例中，前玻璃3由丙烯酸合成树脂制成，而灯体2由诸如ABS和AAS合成树脂制成。即，在上述合成树脂材料的结合中，最好是一个工件(即前玻璃3)的热变形温度和热熔温度比另一工件(即灯体2)的要高。在这些树脂材料的结合中，一个工件W(在本实施例中为前玻璃3)的材料嵌入到另一工件W(在本实施例中为灯体2)中，以使两工件W能牢固地连接到一起。即，在熔接过程中，形成了嵌入式熔接。当熔接接头冷却并固化后，两工件会相互牢固连接。
图6表示了车灯的另一实例，它构成了本发明的第二实施例。
在第一实施例中，是通过将合成树脂制成的前玻璃3与由合成树脂制成的灯体相熔接而形成车灯1。但在车灯中，其前玻璃也可由颜色不同的第一和第二玻璃8和9构成，或者其灯体由多个颜色不同的零件组成。即，在车灯1中，第二实施例中凸缘8a从第一玻璃8一侧的一个边缘向外(在实施例中是向车灯1的后方或者向图7所示的右方)伸出，所述第一玻璃8由合成树脂制成并且是红色的，而在第二玻璃9的后表面圆周上成形的焊脚9a的端部与上述凸缘8a熔接，所述第二玻璃9为淡黄色，在这种方式下，第二玻璃9的端部嵌入到第一玻璃的凸缘8a的连接面内，从而在凸缘8a的连接面和第二玻璃9的端部之间形成了一个嵌入型熔接接头。这样形成的熔接接头10上会覆盖一层第一玻璃8的深红色，不会对车灯的最终外观产生负作用。在上述方式下将第一和第二玻璃8和9连接起来时，可以采用振动式熔接方法(将在后文描述)。
图8表示用于实行依据本发明上述振动式熔接方法的熔接装置。
一般说来，熔接装置11通过电磁振动而在工件W的熔接部分之间产生摩擦热，以熔化熔接部分的材料，然后通过冷却来固化熔接部分，从而将工件W连接起来。熔接装置11包括：一个下部接收夹具12(在固定侧)，其上表面上成形有一凹槽12a，凹槽12a内装有灯体2；一个上部接收夹具13(在可移动侧)，其下表面上形成有一凹槽13a，凹槽13a内装有前玻璃3；一个用于使上部接收夹具13进行电磁振动的振动发生装置14。
在振动发生装置14中，一个振动器17通过大刚度弹性元件16和16从一顶板15的下表面上以下述方式悬挂下来，即振动器17可以水平(左右)移动。另外，电磁铁18和18设置在振动器17的两侧；即，它们通过振动器17而相互对置。上部接收夹具13紧固在振动器17的下表面上。由此，因为右边和左边的电磁铁18和18交替充电，所以振动器17被右边和左边的电磁铁交替吸引；即，振动器17水平(在双向箭的A的方向上)振动，使得上接收夹具13随振动器17一起振动。在该实施例中，振动器17的电磁铁振动是一种水平振动，其频率为240Hz。该电磁振动发生方法不总限定于上述方式。即，在不脱离本发明的范围内，很明显，本领域技术人员可以做出多种改进和变化形式。
依据这种结构装置，一灯体2(第二工件)被装入下部接收夹具12的上表面上成形的凹槽12a中，同时，沿凸缘2a的周围形成的排水肋7装配在下部接收夹具12上成形的槽12b中，并且前玻璃3(第一工件)被牢固地设置在上部接收夹具13的下表面上成形的凹槽13a中。在这种情况下，在适当抬升装置(未表示)的作用下，下部接收夹具12向上移动，直到工件(灯体2和前玻璃3)被夹持在下部接收夹具12和上部接收夹具13之间时为止，即两工件W的连接部分在压力下相互接触；特别是，前玻璃3的焊脚3a的端部在压力下与灯体2的凸缘2a的表面相接触。在这种情况下，起动上述振动发生装置11以产生振幅约1至1.2mm的电磁振动，以在施压方向的垂直方向上振动上部接收夹具，从而在工件W的接合面处产生摩擦热。
依据本发明的振动式熔接方法，在频率大约240Hz、振幅1至1.2mm的小振动下就可实现熔接作业。因而，相对于产品结构来说，减少了制造上的限制。为此，由此方法可以熔接多种工件。例如，即使在前玻璃3的焊脚3a(连接部分)很短的情况下，或者在前玻璃3的焊脚3a相对于灯体2的连接部分弯曲90°的情况下，亦或在熔接线是一种简单的三次曲面的情况下，总能完满地实现熔接作业。
为了实现本发明的振动式熔接方法，灯体2至少应在凸缘2a的圆周部分上带有排水肋7，如前玻璃3的振动方向上所示，所述排水肋相互对置。
两工件W连接部分的材料在摩擦热作用下热变形或熔化，并且前玻璃3(两工件之一)的焊脚3a的端部嵌入到灯体2(另以工件)的凸缘2a的表面中，同时，焊脚3的端部被灯体凸缘2a的熔化材料所包围。在这种情况下，电磁振动停止，并且通过冷却使工件的熔接接头固化，同时使工件保持受压状态。结果是，两工件的连接部分形成了嵌入型熔接接头，即前玻璃3的焊脚3a的端部牢固地焊接在灯体2的凸缘2a的表面上(参见图3至图5)。
在上述实施例中，下部接收夹具12的形状如下，即灯体2安装在其凹槽12a内，并且通过将灯体2凸缘2a的外圆周弯折而形成的排水肋7安装在上述凹槽12a周围形成的槽12b内，这样，灯体2的侧壁被固定而不共振。因此，可以可靠地产生摩擦热。
在图8和图9所示的振动式熔接方法中，前玻璃3的焊脚3a在压力下与灯体2的凸缘2a相接触，并通过振动产生摩擦热。因此，只要焊脚3a振动来摩擦凸缘2a表面，前玻璃(工件之一)表面就可以是凸状的。即，在本发明方法中，前玻璃3的表面不总限于平面。
图10用于说明本发明的另一实施例，它表示了前玻璃焊脚的一个实例。
即，前玻璃3的焊脚3a在压力下与灯体2的凸缘2a的连接部分相接触，并产生摩擦热。结果是，焊脚3的端部受热熔化并熔接到灯体2的连接部分上。因此，如果焊脚3a的端部是很尖的锐角，则当焊脚3a最初在压力下与灯体2的凸缘2a的连接部分相接触时，焊脚3a的端部就会切入凸缘2a的表面，从而使焊脚振动变得困难。因此，如图10(a)和10(b)所示，焊脚3a的端部制成如下形状，即它呈锥形且具有圆头，或者具有半球形顶端，从而焊脚3a可以在灯体2的凸缘2a表面上平滑地振动。
本发明的车灯设计成上述形式。因此，在制造中，由于前玻璃的焊脚端部嵌入到灯体凸缘表面内，所以灯体和前玻璃的连接部分可以可靠地熔接在一起。另外，即使在熔接两块玻璃时，两玻璃之一的连接部分也会嵌入到另一玻璃的连接部分中；即，两玻璃被牢固地熔接在一起。
本发明的振动式熔接方法也可用于灯体很深的车灯中。即，该方法改进成如下形式，当作为移动侧工件的前玻璃振动时，作为固定侧工件的灯体的侧壁可不随前玻璃的振动而共振。因此，在两工件的连接部分能产生足够高的摩擦热，并且工件以下述方式熔接到一起，即前玻璃的焊脚端部嵌入到灯体凸缘的表面中去。
实行本发明振动式熔接方法的熔接装置结构简单、操作可靠。与采用热板式熔接方法或超声波熔接方法形成的传统车灯相比，依据本发明的车灯外观优美且制造时间短。在实际应用中这些效果大为有益。
为了实行本发明的振动式熔接方法，从前玻璃振动方向上看，至少在灯体凸缘周围部分带有排水肋。
依据这种设计形式的车灯，通过弯折灯体凸缘外部圆周部分而形成的排水肋可抖落水滴，否则，当汽车在雨天行驶时，上述雨滴会经过灯体的侧壁而流到灯体后壁上，即这种车灯能够防止水滴通过灯体后壁上形成的通气孔而流入灯室中。
另外，当车灯依据振动式熔接方法成形时，排水肋可装配于在下部接收夹具凹槽周围形成的槽内。因此，即使灯室很深，灯体侧壁也可以被牢固地夹持。因此，在制造期间，灯体不会随前玻璃焊脚振动而共振，并从而可靠地产生摩擦热，由此使前玻璃牢固地熔接在灯体上。在实际应用中，本发明这些效果或优点会大为有益。

Claims (13)

1.一种车灯，包括：
一个由合成树脂制成并且具有一开口的灯体；以及
一块由合成树脂制成的前玻璃；
其中，车灯组成元件中包括有待熔接在一起的两个元件，所述有待熔接在一起的两个元件包括
具有第一连接部分的第一元件；和
具有第二连接部分的第二元件，其特征在于，
所述第一元件的第一连接部分以下述方式熔接到第二元件的第二连接部分上，即第一和第二连接部分之一嵌入到另一连接部分中。
2.如权利要求1所述的车灯，其特征在于，
所述有待熔接在一起的两个元件包括作为所述第一元件的灯体和作为所述第二元件的前玻璃，
所述第一连接部分是一个从灯体开口的周边部分侧向伸出且具有一连接表面的凸缘；
所述第二连接部分是一个在前玻璃的后表面的周边部分上形成的焊脚，其中前玻璃的焊脚端部嵌入到灯体凸缘的连接表面中，从而在所述凸缘的连接表面和前玻璃的焊脚部分之间形成嵌入型熔接接头。
3.如权利要求2所述的车灯，其特征在于，焊脚端部为圆顶的锥形。
4.如权利要求2所述的车灯，其特征在于，焊脚端部为半球形。
5.权利要求1所述的车灯，其特征在于，所述前玻璃包括第一玻璃和第二玻璃，所述有待熔接在一起的两个元件包括作为所述第一元件的第一玻璃和作为所述第二元件的第二玻璃，
所述第一连接部分是一个从第一玻璃的周缘部分侧向伸出并具有一连接表面的凸缘；
所述第二连接部分是一个在第二玻璃的后表面的周缘部分上形成的焊脚，其中，第二玻璃的焊脚端部嵌入到第一玻璃凸缘的连接表面中，从而在所述凸缘连接表面和第二玻璃的焊脚之间形成嵌入型熔接接头。
6.如权利要求5所述的车灯，其特征在于，第一和第二玻璃是颜色互不相同的彩色玻璃。
7.如权利要求2至4中任一项所述的车灯，其特征在于，还包括：
一个从灯体凸缘的外周边部分延伸的排水肋，该排水肋向灯体后壁弯折。
8.如权利要求7所述的车灯，其中，排水肋的端部截面呈锐角形式。
9.如权利要求7所述的车灯，其中，排水肋仅成形于车灯的下部。
10.一种车灯的振动式熔接方法，所述车灯包括
一个由合成树脂制成并且具有一开口的灯体；以及
一块由合成树脂制成的前玻璃；
其中，车灯组成元件中包括有待熔接在一起的两个元件，所述有待熔接在一起的两个元件包括第一元件和第二元件，所述方法包括以下步骤：
(a)将具有一第一连接部分的第一元件装配到下部接收夹具中且使第一连接部分面朝上；
(b)固定第一元件以使第一连接部分不在振动方向上共振；
(c)将具有一第二连接部分的第二元件配装到上部接收夹具中，并使第二元件的第二连接部分与第一元件的第一连接部分的上表面相邻接；
(d)向上移动下部接收夹具，直到第一元件的第一连接部分以预定压力抵压在第二元件的第二连接部分上，所述上部接收夹具牢固地固定在一振动发生装置的下端；和
(e)在与预定压力施加方向垂直的方向上振动上部接收夹具，以便在第一和第二元件的接触区域上产生摩擦热，从而所述第一元件的第一连接部分以下述方式熔接到第二元件的第二连接部分上，即第一和第二连接部分之一嵌入到另一连接部分中。
11.如权利要求10所述的方法，其特征在于，第二元件是带有焊脚的所述玻璃，而第一元件是带有凸缘的灯体，
灯体开口的周边部分牢固地置于下部接收夹具上并被紧固，以使开口的周边部分不会在振动方向上共振动，
玻璃的焊脚端部紧靠在灯体凸缘的上表面上，
此后，下部接收夹具向上移动，直到灯体凸缘被推压到玻璃焊脚端部上，以向灯体凸缘的上表面和玻璃焊脚的接触区域施加一预定压力，以及
在这种状态下，上部接收夹具在垂直于所述预定压力施加方向的方向上振动。
12.如权利要求10所述的方法，其特征在于，所述前玻璃包括第一玻璃和第二玻璃，第一元件是所述第一玻璃，而第二元件是与第一玻璃颜色不同的所述第二玻璃。
13.如权利要求11所述的方法，其特征在于，沿作为第一元件的灯体凸缘外周边成形的一排水肋牢固地安装在下部接收夹具中成形的一个安装槽内，从而当上部接收夹具振动时，防止了灯体开口的圆周部分的共振。
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US6017141A (en) 2000-01-25
US6159317A (en) 2000-12-12

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