CN1266786A - 车辆用灯具及其制造方法 - Google Patents

车辆用灯具及其制造方法 Download PDF

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CN1266786A
CN1266786A CN00104008A CN00104008A CN1266786A CN 1266786 A CN1266786 A CN 1266786A CN 00104008 A CN00104008 A CN 00104008A CN 00104008 A CN00104008 A CN 00104008A CN 1266786 A CN1266786 A CN 1266786A
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玉井裕之
泷秀雄
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Koito Manufacturing Co Ltd
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    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove joints
    • B29C66/1244—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove joints
    • B29C66/1246—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove
    • B29C66/12469—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove being asymmetric
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove joints
    • B29C66/1248—Interpenetrating groove 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
    • B29C66/50—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
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    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Q—ARRANGEMENT OF SIGNALLING OR LIGHTING DEVICES, THE MOUNTING OR SUPPORTING THEREOF OR CIRCUITS THEREFOR, FOR VEHICLES IN GENERAL
    • B60Q1/00—Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor
    • B60Q1/26—Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor the devices being primarily intended to indicate the vehicle, or parts thereof, or to give signals, to other traffic
    • B60Q1/2607—Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor the devices being primarily intended to indicate the vehicle, or parts thereof, or to give signals, to other traffic comprising at least two indicating lamps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • 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
    • F21S41/20—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/28—Cover glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3055—Cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/747—Lightning equipment
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
    • F21W2102/00—Exterior vehicle lighting devices for illuminating purposes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
    • F21W2107/00—Use or application of lighting devices on or in particular types of vehicles
    • F21W2107/10—Use or application of lighting devices on or in particular types of vehicles for land vehicles

Abstract

一种车辆用灯具及其制造方法,具有一体化的透镜,是将先冲压透镜与后冲压透镜接合,并沿这些透镜的接合部设置从透镜面向着后方立起的立起肋,并且先冲压透镜的立起肋的高度高于后冲压透镜的立起肋。在用可动模和先压模及后压模成形一体化透镜时,提高了先冲压透镜成形时其立起肋与可动模之间的密合性,能可靠地将先冲压透镜保持于可动模中,可防止成形不良,提供具有高质量透镜的车辆用灯具。

Description

车辆用灯具及其制造方法
本发明涉及具有由多块透镜成形为一体的透镜的车辆用灯具，尤其涉及可对先冲压(先打ち)透镜和后冲压(后打ち)透镜接合成一体的透镜的成形作业性加以改善的车辆用灯具及其制造方法。
在例如汽车后部组合灯那种将具有多种功能的辅助灯做成一体的灯具上，安装在灯具主体前面开口部上的透镜是将根据各辅助灯而分别使用不同颜色的树脂成形的透镜做成一体。这种一体化透镜往往用所谓多色成形法形成，是将一色的透镜用一个金属模先进行树脂成形，然后将成形的一个透镜放入另一个金属模中，在此状态下将另一个透镜进行树脂成形，由此做成一个透镜与另一个透镜成为一体的透镜。本说明书将先行的树脂成形称为“先冲压”，把后行的树脂成形称为“后冲压”。譬如图7所示的后部组合灯用的一体化透镜2A就是把尾灯/停车灯用的红色透镜3A与倒车灯用的白色(透明)透镜4做成一体化的透镜。这种一体化透镜2A的制造方法譬如是通过先冲压来形成白色透镜4A，用该先冲压形成的白色透镜4A、再通过后冲压成形来形成红色透镜3A。另外，这种一体化透镜为了提高先冲压透镜与后冲压透镜的接合强度，如该图所示，沿各透镜接合的接合部预先设立从透镜面立起的立起肋31A、41A，并在这些立起肋31A、41A的侧面将各透镜3A、4A相互接合。通过设立这样的立起肋，可以扩大透镜的接合面积，形成接合强度高的多色成形透镜。
不过，在形成上述透镜的场合，如图8(a)所示，是把上模作为可动模MK，并把形成白色透镜4A的下模作为先压模FK、形成红色透镜3A的下模作为后压模SK。在可动模MK上形成先冲压透镜和后冲压透镜成形用的空腔面C1，在先压模FK上则形成空腔面C2，该空腔面C2和前述可动模MK一起构成先冲压透镜成形用的空腔FC，又与前述可动模MK的空腔面C1的局部抵接而使形成后冲压透镜的空腔部分无效。另外，如图8(b)所示，在后压模SK上形成空腔面C3，该空腔面和前述可动模MK一起构成后冲压透镜成形用的空腔SC。
并且，如图9(a)所示，在将可动模MK与先压模FK对合后，就用由前述空腔面C1、C2构成的空腔FC成形先冲压透镜4A，然后如图9(b)所示，将成形后的先冲压透镜4A保持在可动模MK中脱模，接着如图8(b)所示，将可动模MK与后压模SK对合，利用空腔面C1、C3，在除了先冲压透镜4A以外的区域构成空腔SC成形后冲压透镜3A。
采用上述的透镜成形方法时，如图9(a)所示，在可动模MK上，除了有形成先冲压透镜4A的立起肋41A用的空腔部分C21，还形成了空腔部分C22，用于形成与该立起肋41A对合的后冲压透镜3A的立起肋31A，但在进行先冲压成形时，先压模FK的一部分C23进入前述后冲压透镜3A的立起肋31A的空腔部分。因而先成形后的先冲压透镜4A的立起肋41A在其外面接触先压模FK的空腔部分C23。因此，在进行了先冲压成形后将可动模脱模时，如图9(c)所示，先冲压透镜4A的立起肋41A与先压模FK的前述空腔部分C23之间的接触导致的摩擦力等密合力使先冲压透镜4A不能与可动模MK整体脱模，而是残留在先压模FK中。因此，即使要进行后面的后冲压透镜的成形工序，也无法成形一体化的透镜。另外，一旦成形后的先冲压透镜残留在先压模中，后面的先冲压透镜成形也不能进行，结果是一体化透镜的成形性差，且难以实现高质量的透镜成形。
本发明的目的在于提供一种车辆用灯具及其制造方法，其先冲压透镜能可靠地以可动模为基础进行脱模，得到成形性好，质量佳的透镜。
本发明的车辆用灯具具有将先冲压透镜和后冲压透镜接合、并沿前述两个透镜的接合部设有从透镜面向后方立起的肋的一体化透镜，其特点是，前述先冲压透镜的前述立起肋高于前述后冲压透镜的立起肋。这里，最好将前述先冲压透镜的立起肋的厚度做成比前述后冲压透镜的立起肋薄。
本发明的车辆用灯具的制造方法包括以下工序：用可动模和先压模将先冲压透镜成形，用前述可动模和后压模将要与前述先冲压透镜接合的后冲压透镜成形以制造出前述先冲压透镜与后冲压透镜形成一体的透镜，其特点是，在前述先冲压透镜的成形工序中，在与前述后冲压透镜间的接合部一体地形成从透镜面向着后方立起的规定高度的立起肋，且在前述后冲压透镜的成形工序中，一体地形成与前述先冲压透镜的立起肋接合且高度低于前述先冲压透镜立起肋的立起肋。
本发明将先冲压透镜的立起肋做成高于后冲压透镜的立起肋，故即使是用可动模、先压模及后压模来成形一体化透镜，也可在先冲压透镜成形时提高立起肋与可动模之间的密合性，且能将先冲压透镜可靠地保持在可动模中，可防止成形不良。而且，可防止主要由立起肋引起的气孔，提高灯具的外表美观性。
对附图的简单说明
图1是本发明实施形态的灯具的主视图。
图2是沿图1中AA线的放大剖视图。
图3是图2的主要部分放大剖视图。
图4是本发明中使用的成形装置的主要部分剖视图。
图5是说明本发明的透镜成形方法的工序图。
图6是说明本发明中一个作用效果的主要部分剖视图。
图7是传统的一体化透镜一例的剖视图。
图8是传统的一体化透镜成形用的成形装置的局部剖视图。
图9是说明传统制造方法的缺点的剖视图。
以下结合附图说明本发明的实施形态。图1是将本发明的车辆用灯具的用于汽车后部组合灯的实施形态的主视图，图2是沿其AA线的剖视图。本实施形态是将尾灯/停车灯T&SL与倒车灯BUL做成一体的后部组合灯RCL，在灯具主体1的前面开口部对应前述各灯T&SL、BUL而装有将红色透镜3和白色透镜4一体化的一体化透镜2，在设于前述灯具主体1的开口边缘上的密封槽1a内用密封剂5将设在其周边部的密封脚21封住。另外，在前述灯具主体1的内面，沿前述倒车灯BUL的周边一体地形成向前方伸出的灯罩1b，用该灯罩1b将前述灯具主体1内划分成前述各灯的灯室11、12。在前述倒车灯BUL的灯室12内，用在前述灯具主体1的背面开口的灯泡安装孔13中安装的灯泡座14支承作为光源的灯泡15。另外，在前述尾灯/停车灯T&SL的灯室11内也同样用灯泡座16来支承灯泡17。
前述一体化的透镜2如图3中包含与前述红色透镜3一体化的白色透镜4在内的放大剖视图所示，两个透镜3和4的前侧面处于同一个面上，构成平坦面，而且在两个透镜3和4的边界部，透镜3和4都在各自的内侧面形成大致向垂直方向伸出的立起肋31、41，两个透镜3和4在这些立起肋31、41的侧面相互接合。这里，前述白色透镜4的立起肋41的高度尺寸H4、即从透镜面起的立起高度大于红色透镜3的立起肋31的高度尺寸H3，使白色透镜4的立起肋41的前端部比红色透镜3的立起肋31的前端更伸出。另外，白色透镜4的立起肋41的厚度t4小于红色透镜3的立起肋31的厚度t3。
图4说明前述一体化透镜的制造方法。基本上与图9所示的多色成形法相同，使用由可动模MK和先压模FK及后压模SK构成的成形装置。这里，将前述白色透镜4作为先冲压透镜，将红色透镜3作为后冲压透镜成形。在可动模MK上形成可成形先冲压透镜4和后冲压透镜3的空腔面C1的形状，在先压模FK上则形成与前述可动模MK一起构成成形先冲压透镜4用的空腔FC、同时与前述可动模MK的模面抵接以使成形后冲压透镜3用的空腔部分无效的空腔面C2的形状。另外，在后压模SK上形成与前述可动模MK和已先冲压成形的先冲压透镜4一起成形后冲压透镜3用的空腔面C3的形状。这里，在可动模MK的空腔面C1，由于前述的白色透镜4与红色透镜3的各立起肋31、41的高度尺寸不同，故成形白色透镜4的立起肋41的部分C11在相当于肋41前端部的部分对应上述高度差而设有绕到立起肋外侧面的部分C12。
在用前述成形装置成形前述透镜时，首先如图5(a)所示，在将前述可动模MK与先压模FK对合后构成的空腔FC中对前述白色透镜4进行树脂成形以作为先冲压透镜。然后如图5(b)所示，将成形后的白色透镜4保持在可动模MK中进行脱模。这时，成形后的白色透镜4的立起肋41的前端外侧面与可动模MK的空腔面一部C12接触，故白色透镜4的立起肋41与可动模MK的空腔面C1之间的接触面积大于使用图8所示的传统可动模的场合，白色透镜4可靠地保持在可动模MK中。然后如图5(c)所示，将可动模MK与后压模SK对合，在除了先冲压透镜4以外区域的空腔SC中成形红色透镜3作为后冲压透镜。通过该后冲压成形，能够将白色透镜4的立起肋41的外侧面与红色透镜3的立起肋31的侧面接合，成形为前述的一体化透镜2。如前所述，先冲压透镜4的立起肋41的尺寸高于后冲压透镜3的立起肋31，从而可在可动模MK脱模时将先冲压透镜4可靠地保持在可动模MK中，可防止先冲压透镜4残留在先压模FK内，可防止成形不良，且改善成形性。
另外，由于本实施形态是将先冲压透镜、即白色透镜4的立起肋41做成比后冲压透镜、即红色透镜3的立起肋31还薄，故白色透镜4的立起肋41的高度即使如前述那样做得较高，也不会增加该肋41的体积。因此在树脂成形中，不会发生在白色透镜4的立起肋41的前面部位出现“气孔”X、即表面变形成凹状的现象，可形成外表美观的高质量透镜。顺便说一句，如果白色透镜4的立起肋41的厚度大于红色透镜3的立起肋31，则会使白色透镜4的立起肋41的体积增大，在立起肋41对面的透镜面上可能产生“气孔”X。
还有，通过使白色透镜4的立起肋41的高度不同于红色透镜3的立起肋31，可以使两个立起肋的前端面位置不在一个面上。因此，如图6(a)所示，采用两个立起肋31、41的前端面大致处于同一面的传统结构时，譬如入射白色透镜4的立起肋41的外光就会在其前端面反射并透过接合面而入射红色透镜3的立起肋31，故红色透镜3与白色透镜4之间的接合部附近特别明亮。而本发明则如图6(b)所示，入射白色透镜4的立起肋41后在其前端面反射的光在红色透镜3的立起肋31的前端面反射，故不会向红色透镜3的前面一侧射出，不会如前述那样影响外表的美观性。而且在这种场合，虽不能说对外表的美观性有太大影响，但如果与前述的实施形态相反，先冲压透镜是红色透镜，而后冲压透镜为白色透镜，则白色透镜与红色透镜之间的接合部附近会被染红，显著影响外表的美观性，而采用本发明，即使在这种场合白色透镜的这一区域也不会被染红。
以上说明了将本发明用于汽车的将尾灯/停车灯和倒车灯做成一体的后部组合灯的实施形态，而即使是将其他灯具一体化的组合灯、甚至是将3个以上的灯做成一体化的组合灯，在将对应各种灯具的透镜用多色成形法成形时同样可采用本发明，能够成形高质量的透镜。
如上所述，本发明的先冲压透镜的立起肋高度高于与之一体化的后冲压透镜的立起肋，故在用可动模、先压模及后压模成形一体化透镜时，可提高先冲压透镜成形时立起肋与可动模之间的密合性，且能将先冲压透镜可靠地保持在可动模中，能够防止成形不良。又由于先冲压透镜的立起肋厚度小于前述后冲压透镜的立起肋，故可防止主要由立起肋引起的气孔发生。从而，本发明可得到具有成形性好、质量高的透镜的车辆用灯具。

Claims (3)

1.一种车辆用灯具，具有将先冲压透镜和后冲压透镜接合、并沿前述两个透镜的接合部设有从透镜面向着后方立起的肋的一体化透镜，其特征在于，前述先冲压透镜的前述立起肋高度高于前述后冲压透镜的立起肋。
2.根据权利要求1所述的车辆用灯具，其特征在于，前述先冲压透镜的立起肋的厚度比前述后冲压透镜的立起肋薄。
3.一种车辆用灯具的制造方法，包括以下工序：用可动模和先压模将先冲压透镜成形，用前述可动模和后压模将与前述先冲压透镜接合的后冲压透镜成形以制造出前述先冲压透镜与后冲压透镜形成一体的透镜，其特征在于，在前述先冲压透镜的成形工序中，在与前述后冲压透镜间的接合部一体地形成从透镜面向着后方立起的规定高度的立起肋，且在前述后冲压透镜的成形工序中，一体地形成与前述先冲压透镜的立起肋接合且高度低于前述先冲压透镜立起肋的立起肋。
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