JP2005267861A - Manufacturing method of lamp for vehicle, and lamp for vehicle - Google Patents

Manufacturing method of lamp for vehicle, and lamp for vehicle Download PDF

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Publication number
JP2005267861A
JP2005267861A JP2004073798A JP2004073798A JP2005267861A JP 2005267861 A JP2005267861 A JP 2005267861A JP 2004073798 A JP2004073798 A JP 2004073798A JP 2004073798 A JP2004073798 A JP 2004073798A JP 2005267861 A JP2005267861 A JP 2005267861A
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Prior art keywords
lens
housing
conductive film
resin sheet
lamp
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Inventor
Kazuhiro Yamazaki
一廣 山▲ざき▼
Masaru Takiguchi
優 瀧口
Yoji Muramatsu
洋士 村松
Mamoru Kosuge
守 小菅
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Koito Manufacturing Co Ltd
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Koito Manufacturing Co Ltd
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Priority to JP2004073798A priority Critical patent/JP2005267861A/en
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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
    • B29C66/50—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
    • 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
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • 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
    • B29C66/50—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
    • B29C66/543—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 more than two hollow-preforms to form said hollow articles
    • 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
    • B29C66/545—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 one hollow-preform being placed inside the other
    • 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
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1664—Laser beams characterised by the way of heating the interface making use of several radiators
    • 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
    • B29C66/71—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 composition of the plastics material 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
    • 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
    • B29C66/739—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 material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—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 material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—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 material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0003—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular electrical or magnetic properties, e.g. piezoelectric
    • B29K2995/0005—Conductive
    • 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
    • B29L2009/00—Layered products
    • 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
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • 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

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Health & Medical Sciences (AREA)
  • Electromagnetism (AREA)
  • Toxicology (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To enable to form easily a conductive film of a desired pattern with a uniform thickness throughout the effective surface of lens. <P>SOLUTION: This is a manufacturing method of a lamp for a vehicle that has a housing 20 and a lens 30 to cover the front of the housing, and comprises a process of coating a conductive film 70 on a resin sheet 80, a process of forming the resin sheet coated with the conductive film in a prescribed shape, a process of trimming the resin sheet formed as above and making it a lens, and a process of fitting the lens to the housing. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

本発明は新規な車輌用灯具の製造方法及び車輌用灯具に関する。詳しくは、寒冷地における使用に好適であると共に製造が容易な車輌用灯具及びその製造方法に関する。   The present invention relates to a novel method for manufacturing a vehicular lamp and a vehicular lamp. More specifically, the present invention relates to a vehicular lamp that is suitable for use in a cold region and is easy to manufacture, and a method for manufacturing the same.

従来、車輌用灯具の光源にはハロゲン電球等の白熱電球が広く使用されてきたが、近時においては、放電ランプや発光ダイオードを光源として使用する車輌用灯具が出現し、その使用が拡大する傾向が見られる。   Conventionally, incandescent bulbs such as halogen bulbs have been widely used as light sources for vehicle lamps, but recently, vehicle lamps using discharge lamps and light-emitting diodes as light sources have emerged and their use has expanded. There is a trend.

ところで、放電ランプは所望の照度を容易に得られるという利点を有するし、また、発光ダイオードは消費電力が少ないという利点を有する。   By the way, the discharge lamp has an advantage that a desired illuminance can be easily obtained, and the light emitting diode has an advantage of low power consumption.

ところで、上記した放電ランプや発光ダイオードを光源とする場合、発熱量が少なくなるという問題がある。   By the way, when the above-described discharge lamp or light emitting diode is used as a light source, there is a problem that the amount of heat generation is reduced.

従来の白熱電球にあっては、発熱量が大きいため、寒冷地において使用する場合、レンズの表面に雪や氷が付着しても、白熱電球の熱によって雪や氷を溶かすという融雪効果が大きいため、ほとんど問題がなかった。   Conventional incandescent bulbs generate a large amount of heat, so when used in cold regions, even if snow or ice adheres to the surface of the lens, the effect of melting snow by melting the snow and ice with the incandescent bulb's heat is great. So there was almost no problem.

ところが、放電ランプや発光ダイオードにあっては、発熱量が小さいため、融雪効果が小さく、問題である。車輌用灯具は保安部品であるため、レンズに着雪や着氷したままでの走行は前方視界を確保することができなかったり（前照灯の場合）、対向車や後続車に自車輌の挙動を知らしめることができなかったり（標識灯の場合）して、極めて危険である。   However, discharge lamps and light-emitting diodes have a problem in that the amount of heat generated is small and the snow melting effect is small. Since the vehicular lamp is a safety part, driving with snow or icing on the lens cannot secure the front view (in the case of headlights), It is extremely dangerous because the behavior cannot be informed (in the case of a marker lamp).

そこで、熱線によってレンズ表面を暖める抵抗加熱方式の採用が寒冷地対策として有効である考えられる。しかしながら、熱線のレンズへの付与には、印刷、蒸着などの表面処理技術の利用が考えられるが、従来の車輌用灯具の構造、レンズの成形工法をもってしては、レンズの有効面全体に熱線を形成することができない、熱線を所望のパターンに形成することができない、熱線の膜厚を均一に形成することができない、等の問題がある。   Therefore, it is considered that the use of a resistance heating method in which the lens surface is heated by heat rays is effective as a countermeasure for cold regions. However, it is conceivable to use surface treatment techniques such as printing and vapor deposition for the application of heat rays to the lens. However, with the conventional structure of a vehicle lamp and the lens molding method, the heat ray is applied to the entire effective surface of the lens. Cannot be formed, the heat rays cannot be formed in a desired pattern, and the film thickness of the heat rays cannot be formed uniformly.

本発明は、上記した問題に鑑みて為されたものであり、レンズ有効面の全体に亘って所望のパターンの導電膜を均一な膜厚で容易に形成することができるようにすることを課題とする。   The present invention has been made in view of the above-described problems, and an object thereof is to easily form a conductive film having a desired pattern with a uniform film thickness over the entire lens effective surface. And

本発明車輌用灯具の製造方法は、上記した課題を解決するために、樹脂シートに導電膜をコーティングする工程と、導電膜がコーディングされた樹脂シートを所定の形状にフォーミングする工程と、上記フォーミングされた樹脂シートをトリミングしてレンズとする工程と、上記レンズをハウジングに取り付ける工程とを備えたものである。   In order to solve the above-described problems, the method for manufacturing a vehicular lamp according to the present invention includes a step of coating a resin sheet with a conductive film, a step of forming a resin sheet coated with the conductive film into a predetermined shape, and the forming The resin sheet is trimmed to form a lens, and the lens is attached to the housing.

また、本発明車輌用灯具は、上記した課題を解決するために、ハウジングと該ハウジングの前方を覆うレンズを備え、上記レンズは、導電膜がコーティングされた樹脂シートをフォーミングして形成されたものである。   In order to solve the above-described problem, the vehicle lamp of the present invention includes a housing and a lens that covers the front of the housing, and the lens is formed by forming a resin sheet coated with a conductive film. It is.

従って、本発明にあっては、フォーミング前の平板な状態の樹脂シートに導電膜をコーティングするので、レンズの有効面となる部分の全体に亘って、且つ、所望のパターンの導電膜を所望の厚さに容易に付与することができる。   Therefore, in the present invention, since the conductive film is coated on the resin sheet in a flat state before forming, the conductive film having a desired pattern is formed over the entire portion to be the effective surface of the lens. It can be easily applied to the thickness.

本発明車輌灯具の製造方法は、ハウジングと該ハウジングの前方を覆うレンズを備えた車輌用灯具の製造方法であって、樹脂シートに導電膜をコーティングする工程と、導電膜がコーディングされた樹脂シートを所定の形状にフォーミングする工程と、上記フォーミングされた樹脂シートをトリミングしてレンズとする工程と、上記レンズをハウジングに取り付ける工程とを備えたことを特徴とする。   The vehicle lamp manufacturing method of the present invention is a vehicle lamp manufacturing method including a housing and a lens covering the front of the housing, the step of coating the resin sheet with a conductive film, and the resin sheet coated with the conductive film Forming a lens into a predetermined shape, trimming the formed resin sheet to form a lens, and attaching the lens to a housing.

また、本発明車輌用灯具は、ハウジングと該ハウジングの前方を覆うレンズを備えた車輌用灯具であって、上記レンズは、導電膜がコーティングされた樹脂シートをフォーミングして形成されたものであることを特徴とする。   The vehicular lamp according to the present invention is a vehicular lamp that includes a housing and a lens that covers the front of the housing, and the lens is formed by forming a resin sheet coated with a conductive film. It is characterized by that.

従って、本発明にあっては、フォーミング前の平板な状態の樹脂シートに導電膜をコーティングするので、レンズの有効面となる部分の全体に亘って、且つ、所望のパターンの導電膜を所望の厚さに容易に付与することができる。   Therefore, in the present invention, since the conductive film is coated on the resin sheet in a flat state before forming, the conductive film having a desired pattern is formed over the entire portion to be the effective surface of the lens. It can be easily applied to the thickness.

請求項２に記載した発明にあっては、上記レンズをレーザー溶着によってハウジングに取り付けるので、レンズとハウジングとを数ｍｍという僅かな溶着幅によって結合することができるので、フォーミング前の樹脂シートの厚さを薄いものとすることができ、フォーミング時の整形性が良好になる。   In the invention described in claim 2, since the lens is attached to the housing by laser welding, the lens and the housing can be coupled with a slight welding width of several mm, so the thickness of the resin sheet before forming The thickness can be reduced, and the formability during forming is improved.

以下に、本発明車輌用灯具の製造方法及び車輌用灯具を実施するための最良の形態について添付図面を参照して説明する。   The best mode for carrying out the method for manufacturing a vehicle lamp and the vehicle lamp of the present invention will be described below with reference to the accompanying drawings.

先ず、本発明にかかる車輌用灯具の第１の実施の形態について、図１を参照して説明する。   First, a first embodiment of a vehicular lamp according to the present invention will be described with reference to FIG.

車輌用灯具１０は前方が開口した凹部を有するハウジング２０の前面開口がレンズ３０によって覆われて灯室４０が形成され、ハウジング２０の後部に取着されたバックカバー５０に放電バルブ６０が取着されて成る。なお、放電バルブ６０には図示しない放電回路と接続されたバルブソケット６１が取着され、放電バルブ６０にはバルブソケット６１を介して放電回路から放電電圧が供給されるようになっている。   In the vehicular lamp 10, a front opening of a housing 20 having a recess opened at the front is covered with a lens 30 to form a lamp chamber 40, and a discharge bulb 60 is attached to a back cover 50 attached to the rear portion of the housing 20. Made up. Note that a bulb socket 61 connected to a discharge circuit (not shown) is attached to the discharge bulb 60, and a discharge voltage is supplied to the discharge bulb 60 from the discharge circuit via the bulb socket 61.

上記レンズ３０の内面には所望のパターンの導電膜７０が形成されている。図示は省略してあるが、導電膜７０には通電可能とされており、導電膜７０への通電により導電膜７０が抵抗加熱され、これによって、レンズ３０の表面温度が融雪可能な温度まで上昇するようにされている。また、レンズ３０の外表面には撥水性を有する膜（撥水コート）をコーティングしても良く、これにより、レンズ外表面に付着した雪や氷が、レンズ３０外表面との界面の溶融により、速やかに除去される。   A conductive film 70 having a desired pattern is formed on the inner surface of the lens 30. Although not shown, the conductive film 70 can be energized, and the conductive film 70 is resistance-heated by energization of the conductive film 70, thereby increasing the surface temperature of the lens 30 to a temperature at which snow melting is possible. Have been to. In addition, a film having water repellency (water repellent coating) may be coated on the outer surface of the lens 30, so that snow and ice adhering to the outer surface of the lens are melted at the interface with the outer surface of the lens 30. Quickly removed.

上記導電膜７０への通電は適宜の時期に為されればよい。例えば、放電バルブ６０への通電時、エンジンの始動時、運転者が所望した時期等に通電が為されればよい。   The conductive film 70 may be energized at an appropriate time. For example, the energization may be performed when the discharge bulb 60 is energized, when the engine is started, or when the driver desires.

上記レンズ３０は、耐衝撃性、耐候性に優れた透明な熱可塑性プラスチック、例えば、ＰＣ（ポリカーボネート）、ＰＭＭＡ（アクリル樹脂）、ＡＳ（アクリロニトリル／スチレン樹脂）等を使用した加熱加圧成形によって形成されている。また、ハウジング２０は、耐久性、耐衝撃性等に優れた構造体用の熱可塑性プラスチック、例えば、ＰＣ／ＡＢＳ（アクリロニトリル／ブタジエン／スチレン樹脂）アロイ等の、ＰＣ系アロイ、ＰＢＴ（ポリブチレンテレフタレート）／ＰＣアロイ等のＰＢＴ系アロイ等を使用した射出成形によって形成されている。また、バックカバー５０は、耐久性、耐衝撃性に優れ、比較的安価な構造体用熱可塑性プラスチック、例えば、ＰＰ（ポリプロピレン）等を使用した射出成形によって形成されている。しかしながら、ここに挙げた、各材料樹脂及び成形方法は、例示であり、各部の材料樹脂や成形方法が上記したものに限定されることを意味するものではない。   The lens 30 is formed by heat and pressure molding using a transparent thermoplastic having excellent impact resistance and weather resistance, such as PC (polycarbonate), PMMA (acrylic resin), AS (acrylonitrile / styrene resin), and the like. Has been. In addition, the housing 20 is made of a PC-based alloy such as PC / ABS (acrylonitrile / butadiene / styrene resin) alloy such as PC / ABS (acrylonitrile / butadiene / styrene resin), PBT (polybutylene terephthalate) having excellent durability and impact resistance. ) / Injection molding using a PBT alloy such as a PC alloy. Further, the back cover 50 is formed by injection molding using a thermoplastic thermoplastic for structure, such as PP (polypropylene), which is excellent in durability and impact resistance and is relatively inexpensive. However, each material resin and molding method listed here are examples, and do not mean that the material resin and molding method of each part are limited to those described above.

上記レンズ３０とハウジング２０とはレーザー溶着によって接合されることが好ましい。レーザー溶着によれば、互いの溶着幅が数ｍｍで強固に接合することができ、好ましい。また、ハウジング２０とバックカバー５０との結合は、放電バルブ６０の交換等を考慮した場合、両者の間にパッキング等のシール材５１を介在させたネジ止めにより着脱可能な状態で結合することが好ましいが、勿論、その他の結合構造によって結合しても構わない。   The lens 30 and the housing 20 are preferably joined by laser welding. Laser welding is preferable because it can be firmly joined with a welding width of several mm. Further, the housing 20 and the back cover 50 can be connected in a detachable state by screwing with a sealant 51 such as packing interposed between them when considering the replacement of the discharge bulb 60 or the like. Of course, it may be bonded by other bonding structures.

なお、本発明において、バックカバー５０は必須の部材ではない。バックカバー５０を使用しない場合は、ハウジング２０に放電バルブ６０を支持させるようにしても良い。また、「ハウジング」という名称は一応の名称であって、例えば、その内面に反射面が形成された場合、「リフレクタ」等の名称で呼称される場合もある。   In the present invention, the back cover 50 is not an essential member. When the back cover 50 is not used, the discharge bulb 60 may be supported by the housing 20. The name “housing” is a temporary name. For example, when a reflecting surface is formed on the inner surface, the name “housing” may be used.

次に、上記した車輌用灯具１０の製造方法について、図２乃至図６を参照して説明する。本発明車輌用灯具の製造方法は、レンズ３０の成形及びレンズ３０とハウジング２０との接合に特徴がある。   Next, a method for manufacturing the vehicle lamp 10 will be described with reference to FIGS. The method for manufacturing a vehicular lamp according to the present invention is characterized by molding the lens 30 and joining the lens 30 and the housing 20.

先ず、レンズの基材として、耐衝撃性、耐候性に優れた透明な熱可塑性プラスチックのシート８０を用意する（図２参照）。その具体的なプラスチックの例としては前記したようなものがある。この樹脂シート８０の厚さは０．５ｍｍ乃至５．０ｍｍの範囲のものがよい。   First, a transparent thermoplastic sheet 80 having excellent impact resistance and weather resistance is prepared as a lens substrate (see FIG. 2). Specific examples of the plastic include those described above. The thickness of the resin sheet 80 is preferably in the range of 0.5 mm to 5.0 mm.

次いで、上記樹脂シート８０の一方の面に導電膜７０を所望のパターンで形成する（図３参照）。上記導電膜７０の付与は、銀などの高導電性金属を含んだインクを印刷する印刷工法、アルミニウムや銅などの金属或いは金属化合物（透明性を有するＩＴＯ（インジウム・スズ化合物）等）をターゲットとした蒸着工法等適宜の方法によって付与して構わない。そして、導電膜７０は次の熱成形に耐えうるように高延伸性を有することが好ましい。   Next, the conductive film 70 is formed in a desired pattern on one surface of the resin sheet 80 (see FIG. 3). The conductive film 70 is applied by a printing method for printing ink containing a highly conductive metal such as silver, a metal such as aluminum or copper, or a metal compound (such as ITO (indium tin compound) having transparency). It may be applied by an appropriate method such as a vapor deposition method. And it is preferable that the electrically conductive film 70 has high stretchability so that it can endure the following thermoforming.

次に、導電膜７０がコーティングされた樹脂シート８０を所定の形状に成形するフォーミングを行う（図４参照）。このフォーミングは、樹脂シート８０を加熱軟化させると共に真空によって吸引して金型に押しつけたり、圧縮空気の空圧によって金型に押しつけたり、２つの金型の間で圧縮したりする、いわゆる熱成形によって行われる。   Next, forming for forming the resin sheet 80 coated with the conductive film 70 into a predetermined shape is performed (see FIG. 4). This forming is so-called thermoforming in which the resin sheet 80 is softened by heating and is sucked by vacuum and pressed against the mold, pressed against the mold by air pressure of compressed air, or compressed between the two molds. Is done by.

上記フォーミング工程によって所定の形状に成形された樹脂シート８０からレンズ３０として使用する部分を切り取る（図５参照）。樹脂シート８０を金型に対して押しつける方向（図４の矢印参照）に長く沿う部分８０ａは成形時に大きく延伸されるため、肉厚が極端に薄くなった部分が生じる惧がある。そのため、押しつけ方向に極端な段差が生じていない部分をレンズとして使用するために、当該部分を他の部分８０ａから切り離してレンズ３０とする。なお、この切り離しはレーザーによって行うのが好ましい。   A portion to be used as the lens 30 is cut out from the resin sheet 80 formed into a predetermined shape by the forming process (see FIG. 5). Since the portion 80a that extends along the direction in which the resin sheet 80 is pressed against the mold (see the arrow in FIG. 4) is greatly stretched during molding, there is a possibility that a portion having an extremely thin thickness may be generated. Therefore, in order to use a portion where no extreme step is generated in the pressing direction as a lens, the portion is separated from the other portion 80a to form the lens 30. This separation is preferably performed by a laser.

そして、上記のようにして形成したレンズ３０をハウジング２０に接合し（図６参照）、そして、放電バルブ６０を支持したバックカバー５０をハウジング２０に取着して車輌用灯具１０が形成される。なお、レンズ３０とハウジング２０との接合はレーザー溶着によって行うのが好ましい。レーザー溶着は溶着幅が数ｍｍあれば十分であるので、厚さ０．５ｍｍ乃至５．０ｍｍの樹脂シート８０を熱成形して形成されるレンズ３０を強固にハウジング２０に接合することができる。   Then, the lens 30 formed as described above is joined to the housing 20 (see FIG. 6), and the back cover 50 supporting the discharge bulb 60 is attached to the housing 20 to form the vehicular lamp 10. . The lens 30 and the housing 20 are preferably joined by laser welding. Since the laser welding is sufficient if the welding width is several mm, the lens 30 formed by thermoforming the resin sheet 80 having a thickness of 0.5 mm to 5.0 mm can be firmly joined to the housing 20.

図７に本発明車輌灯具の第２の実施の形態を示す。   FIG. 7 shows a second embodiment of the vehicle lamp of the present invention.

車輌用灯具１０Ａは、ハウジング９０がハウジングベース９１とエクステンション９２とから成り、エクステンション９２を介してレンズ３０Ａを取り付け、ハウジング９０とレンズ３０Ａとによって画成された灯室４０Ａ内に放電バルブ６０を支持したリフレクタ５０Ａが傾動可能に配置されて成る。   In the vehicular lamp 10A, a housing 90 includes a housing base 91 and an extension 92, a lens 30A is attached via the extension 92, and a discharge bulb 60 is supported in a lamp chamber 40A defined by the housing 90 and the lens 30A. The reflector 50A is arranged to be tiltable.

ハウジングベース９１は、前方に開口した容器状をしており、その開口縁に嵌合溝９１ａが形成されている。そして、このようなハウジングベース９１は、耐久性、耐衝撃性に優れ、比較的安価な構造体用熱可塑性プラスチック、例えば、ＰＰ（ポリプロピレン）等を使用した射出成形によって形成されている。   The housing base 91 has a container shape opened forward, and a fitting groove 91a is formed at the opening edge. The housing base 91 is formed by injection molding using a structural thermoplastic having excellent durability and impact resistance and relatively inexpensive, such as PP (polypropylene).

エクステンション９２は前端開口部９２ａに対して後端開口部９２ｂが小さい、前広がりの形状をしており、後端開口部９２ｂは上記ハウジングベース９１の開口縁の内縁より僅かに内側まで突出しており、前端開口部９２ａはハウジングベース９１の外径より外側に位置している。そして、後端開口部９２ｂより外側に寄った後面からは嵌合縁９２ｃが後方へ向かって突出している。そして、このようなエクステンション９２は、耐久性、耐衝撃性等に優れた構造体用の熱可塑性プラスチック、例えば、ＰＣ／ＡＢＳ（アクリロニトリル／ブタジエン／スチレン樹脂）アロイ等の、ＰＣ系アロイ、ＰＢＴ（ポリブチレンテレフタレート）／ＰＣアロイ等のＰＢＴ系アロイ等を使用した射出成形によって形成されている。   The extension 92 has a front-opening shape in which the rear-end opening 92b is smaller than the front-end opening 92a, and the rear-end opening 92b protrudes slightly inward from the inner edge of the opening edge of the housing base 91. The front end opening 92 a is located outside the outer diameter of the housing base 91. A fitting edge 92c protrudes rearward from the rear surface that is closer to the outside than the rear end opening 92b. Such an extension 92 is made of a thermoplastic thermoplastic for a structure excellent in durability, impact resistance, etc., for example, a PC alloy such as PC / ABS (acrylonitrile / butadiene / styrene resin) alloy, PBT (PBT). Polybutylene terephthalate) / PC alloy, etc., and formed by injection molding using a PBT alloy.

そして、上記したエクステンション９２は、その嵌合縁９２ｃの後端がハウジングベース９１の嵌合溝９１ａにシール材９３を介して嵌合されることによって、ハウジングベース９１に取り付けられ、これによってハウジング９０が形成される。   The extension 92 is attached to the housing base 91 by fitting the rear end of the fitting edge 92c into the fitting groove 91a of the housing base 91 via the seal member 93, and thereby the housing 90 is fitted. Is formed.

レンズ３０Ａは、上記レンズ３０と同様に、耐衝撃性、耐候性に優れた透明な熱可塑性プラスチック、例えば、ＰＣ（ポリカーボネート）、ＰＭＭＡ（アクリル樹脂）、ＡＳ（アクリロニトリル／スチレン樹脂）等を使用した加熱加圧成形によって形成され、その内面に、上記製造方法と同様の製造方法によって、導電膜７０Ａが形成されている。そして、レンズ３０Ａはレーザー溶着によってエクステンション９２の前部開口部９２ａに一体化される。   As with the lens 30, the lens 30 </ b> A is made of a transparent thermoplastic having excellent impact resistance and weather resistance, such as PC (polycarbonate), PMMA (acrylic resin), AS (acrylonitrile / styrene resin), and the like. The conductive film 70A is formed on the inner surface by the same manufacturing method as that described above. The lens 30A is integrated with the front opening 92a of the extension 92 by laser welding.

この第２の実施の形態にかかる車輌用灯具１０Ａにあっては、シール部、すなわち、ハウジングベース９１とエクステンション９２との結合部（嵌合溝９１ａ、嵌合縁９２ｃ）がエクステンション９２によって前方に対して目隠しされているため、見栄えがよいものとなる。また、エクステンション９２とハウジングベース９１との間は着脱可能であるので、レンズ３０Ａ−エクステンション９２ユニットの交換が可能である。   In the vehicular lamp 10A according to the second embodiment, the seal portion, that is, the coupling portion (the fitting groove 91a and the fitting edge 92c) between the housing base 91 and the extension 92 is moved forward by the extension 92. Since it is blindfolded, it looks good. Since the extension 92 and the housing base 91 are detachable, the lens 30A-extension 92 unit can be replaced.

上記した本発明車輌用灯具及び車輌用灯具の製造方法にあっては、フォーミング前の平板な状態の樹脂シート８０に導電膜７０をコーティングするので、レンズの有効面となる部分の全体に亘って、且つ、所望のパターンの導電膜を所望の厚さに容易に付与することができる。   In the vehicle lamp and the vehicle lamp manufacturing method of the present invention described above, since the conductive film 70 is coated on the resin sheet 80 in a flat state before forming, the entire portion that becomes the effective surface of the lens is covered. In addition, a conductive film having a desired pattern can be easily applied to a desired thickness.

なお、上記した各実施の形態において示した各部の形状及び構造は、何れも本発明を実施するに際して行う具体化のほんの一例を示したものに過ぎず、これらによって本発明の技術的範囲が限定的に解釈されることがあってはならないものである。   It should be noted that the shapes and structures of the respective parts shown in the above-described embodiments are merely examples of implementations in carrying out the present invention, and the technical scope of the present invention is limited by these. It should not be interpreted in a general way.

寒冷地で使用する車輌用灯具に適用して、融雪効果の高い車輌用灯具を安価に得ることができる。   By applying it to a vehicular lamp used in a cold region, a vehicular lamp having a high snow melting effect can be obtained at low cost.

本発明車輌用灯具の第１の実施の形態を示す概略縦断面図である。1 is a schematic longitudinal sectional view showing a first embodiment of a vehicular lamp according to the present invention. 図３乃至図６と共に本発明車輌用灯具の製造方法の実施の形態を示すものであり、本図は樹脂シートを示す概略平面図である。3 to 6 show an embodiment of a method for manufacturing a vehicular lamp according to the present invention, and this figure is a schematic plan view showing a resin sheet. 樹脂シートに導電膜をコーティングした状態を示す概略平面図である。It is a schematic plan view which shows the state which coated the electrically conductive film on the resin sheet. 樹脂シートを熱成形した状態を示す概略断面図である。It is a schematic sectional drawing which shows the state which thermoformed the resin sheet. 熱成形した樹脂シートからレンズをトリミングする状態を示す概略断面図である。It is a schematic sectional drawing which shows the state which trims a lens from the thermoformed resin sheet. レンズをハウジングに接合する状態を示す概略断面図である。It is a schematic sectional drawing which shows the state which joins a lens to a housing. 本発明車輌用灯具の第２の実施の形態を示す概略縦断面図である。It is a schematic longitudinal cross-sectional view which shows 2nd Embodiment of the vehicle lamp of this invention.

符号の説明Explanation of symbols

１０…車輌用灯具、２０…ハウジング、３０…レンズ、７０…導電膜、８０…樹脂シート、１０Ａ…車輌用灯具、３０Ａ…レンズ、７０Ａ…導電膜、９０…ハウジング   DESCRIPTION OF SYMBOLS 10 ... Vehicle lamp, 20 ... Housing, 30 ... Lens, 70 ... Conductive film, 80 ... Resin sheet, 10A ... Vehicle lamp, 30A ... Lens, 70A ... Conductive film, 90 ... Housing

Claims (3)

ハウジングと該ハウジングの前方を覆うレンズを備えた車輌用灯具の製造方法であって、
樹脂シートに導電膜をコーティングする工程と、
導電膜がコーディングされた樹脂シートを所定の形状にフォーミングする工程と、
上記フォーミングされた樹脂シートをトリミングしてレンズとする工程と、
上記レンズをハウジングに取り付ける工程とを備えた
ことを特徴とする車輌用灯具の製造方法。 A method for manufacturing a vehicular lamp comprising a housing and a lens covering the front of the housing,
Coating the conductive film on the resin sheet;
Forming a resin sheet coated with a conductive film into a predetermined shape;
Trimming the formed resin sheet into a lens;
A method for manufacturing a vehicular lamp, comprising: attaching the lens to a housing. 上記レンズをレーザー溶着によってハウジングに取り付ける
ことを特徴とする請求項１に記載の車輌用灯具の製造方法。 The method for manufacturing a vehicular lamp according to claim 1, wherein the lens is attached to the housing by laser welding. ハウジングと該ハウジングの前方を覆うレンズを備えた車輌用灯具であって、
上記レンズは、導電膜がコーティングされた樹脂シートをフォーミングして形成されたものである
ことを特徴とする車輌用灯具。 A vehicular lamp including a housing and a lens covering the front of the housing,
The vehicle lamp according to claim 1, wherein the lens is formed by forming a resin sheet coated with a conductive film.
JP2004073798A 2004-03-16 2004-03-16 Manufacturing method of lamp for vehicle, and lamp for vehicle Pending JP2005267861A (en)

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* Cited by examiner, † Cited by third party
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EP2664496A1 (en) * 2012-05-15 2013-11-20 Odelo GmbH Method for manufacturing motor vehicle lights
JP2019523721A (en) * 2016-06-06 2019-08-29 アルプラ ヴェアケ アルヴィン レーナー ゲゼルシャフト ミット ベシュレンクテル ハフツング ウント コンパニー コマンディートゲゼルシャフトＡｌｐｌａ Ｗｅｒｋｅ Ａｌｗｉｎ Ｌｅｈｎｅｒ ＧｍｂＨ ＆ Ｃｏ． ＫＧ Stretch blow molded plastic container with integrally formed gripping region and method for manufacturing plastic container
JP2022102911A (en) * 2020-12-25 2022-07-07 市光工業株式会社 Mirror device for vehicle and lighting fixture for vehicle

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2664496A1 (en) * 2012-05-15 2013-11-20 Odelo GmbH Method for manufacturing motor vehicle lights
JP2019523721A (en) * 2016-06-06 2019-08-29 アルプラ ヴェアケ アルヴィン レーナー ゲゼルシャフト ミット ベシュレンクテル ハフツング ウント コンパニー コマンディートゲゼルシャフトＡｌｐｌａ Ｗｅｒｋｅ Ａｌｗｉｎ Ｌｅｈｎｅｒ ＧｍｂＨ ＆ Ｃｏ． ＫＧ Stretch blow molded plastic container with integrally formed gripping region and method for manufacturing plastic container
JP2022102911A (en) * 2020-12-25 2022-07-07 市光工業株式会社 Mirror device for vehicle and lighting fixture for vehicle
JP7465206B2 (en) 2020-12-25 2024-04-10 美里工業株式会社 Mirror device for vehicle

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