JP2008018734A - Method for producing lamp - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To easily implement a method for producing a lamp by bonding a light source, a lamp body 3 in which the light source is incorporated, and a reflecting surface reflecting light emitted from the light source is formed, a lens part 4 which transmits the light emitted from the light source and is made to butt the lamp body 3, and a butt part for the lamp body 3 and the lens part 4 together in a secondary injection process. <P>SOLUTION: The method for producing the lamp includes: a primary injection process in which while uneven mold surfaces 1a and 2a for forming the inside and outside surfaces of the lamp body 3 and uneven mold surfaces 1b and 2b for forming the inside and outside surfaces of the lens part 4 are butted together, a resin is injected between the mold surfaces to injection-mold the lamp body 3 and the lens part 4, respectively; a reflecting surface forming process in which the lamp body 3 injection-molded in the primary injection process, a concave mold surface 2c holding a vapor deposition device 5, the reflecting surface 14 is vapor-deposited on the inside surface; and a secondary injection process in which while the lamp body 3 with the reflecting surface 14 formed is made to butt the lens part 4, the lamp body 3 and the lens part 4 are injected secondarily to be integrated. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

The present invention belongs to the technical field of housings such as front lamps, turn signals (including side turn signals), tail lamps and the like mounted on vehicles and the like.

In general, in this kind of housing, a housing body in which a light source (bulb, bulb, light emitting diode, etc.) is assembled and a lens portion formed of a translucent resin material are abutted and the abutting surface is adhered. A die slide injection method is known as a manufacturing method of such a device (see, for example, Patent Document 1). In this product, the primary product 燈 body and lens part are injection molded with the movable mold and fixed mold facing each other, and then the movable mold is slid to match each primary product. Mold matching is performed, and a resin material is secondarily injected into a butt portion between primary products to integrally mold the casing.
Japanese Examined Patent Publication No. 2-38377

By the way, in the conventional case, in order to increase the amount of light and ensure a wide irradiation range,
Although there are some which make the inner surface of the 燈 body into a mirror state and make it a reflection surface (reflector), it has not been proposed to make the inner surface of the 燈 body into a reflection surface in the above-mentioned die slide injection method. Take out the injected cocoon body from the mold once, and after forming the reflective surface on the inner surface of the cocoon body using a reflective surface forming method such as vacuum evaporation or sputtering, set it back on the mold and match the primary products The part was secondarily injected to integrate the eyelid body and the lens part.
Today, however, the lens cut surface has been reduced in the lens part, and the inner surface (reflective surface) of the heel body has been well-understood. In particular, the reflective surface has fingerprints and scratches. In this case, since these can be seen from the outside through the lens part, it becomes a defective product, and therefore it is necessary to be careful in handling the body body after forming the reflecting surface, so that the workability is poor and the yield is low. There is a problem to be solved by the present invention.

The present invention has been created in view of the above circumstances and has been created for the purpose of solving these problems. The invention of claim 1 includes a light source and the light source, and the light source emits on the inner surface. A ridge body formed with a reflective surface that reflects light and molded in a primary injection process using a resin material, and a primary injection process using a translucent resin material that transmits light emitted from the light source, The lens part abutted against the main body and the abutting part between the eyelid body and the lens part are molded in a secondary injection process, and are bonded to the eyelid body and the lens part, and the eyelid body and the lens part are integrated. A method of manufacturing a casing made of a resin material to be converted, wherein a movable mold surface is formed with a concave surface for forming the outer surface of the main body and a convex surface for forming the inner surface of the lens portion. The inner surface of the mold body A fixed mold having a convex surface for forming and a concave surface for forming the outer surface of the lens unit, and a vapor deposition device for forming a reflective surface on the inner surface of the main body. The movable mold is configured to be movable toward and away from the fixed mold. The fixed mold has a concave surface for accommodating the vapor deposition apparatus, and the concave mold surface includes the concave mold surface. A vapor deposition apparatus is accommodated, and the movable mold is moved with respect to the fixed mold to form a concave mold surface for forming the outer surface of the bowl main body and a convex for forming the inner surface of the bowl main body. A primary abutting step of abutting a mold surface, and a convex surface for forming the inner surface of the lens portion and a concave surface for forming the outer surface of the lens portion, for forming the outer surface of the bag body Between the concave surface and the convex surface for forming the inner surface of the bag body, In addition, a resin is injected between a convex surface for forming the inner surface of the lens portion and a concave surface for forming the outer surface of the lens portion, and the bag body and the lens portion are respectively injection molded. A primary injection step, holding the bag main body injection-molded in the primary injection step on the concave mold surface of the movable mold, and the lens portion injection-molded in the primary injection process on the concave mold surface of the fixed mold The movable mold is moved in a direction away from the fixed mold, and then the concave mold surface of the movable mold and the fixed holding the bag body injection-molded in the primary injection step. A secondary abutting step of abutting the concave mold surface containing the vapor deposition device of the mold, a reflection for depositing a reflective surface on the inner surface of the main body by the vapor deposition device accommodated in the concave mold surface of the fixed mold Surface formation step and the reflective surface formation The movable body having the reflective surface formed in the process is held on the concave mold surface of the movable mold, and the lens part injection-molded in the primary injection process is held on the concave mold surface of the fixed mold. The mold is moved in a direction away from the fixed mold, and then the concave mold surface of the movable mold holding the bag main body formed with the reflective surface in the reflective surface forming process and the injection molding in the primary injection process. A third-order abutting step of abutting the concave mold surface of the fixed mold holding the formed lens part, and moving the movable mold away from the fixed mold, and integrating in the secondary injection step. And a taking-out step of taking out the main body and the lens part from the movable mold and the fixed mold.
According to the second aspect of the present invention, a light source, a terminal connected to the light source, the light source and the terminal are incorporated, and a reflection surface for reflecting light emitted from the light source is formed on an inner surface, so that it is opaque. A bag body molded in a primary injection process with a resin material, a lens part molded in a primary injection process with a translucent resin material that transmits light emitted from the light source, and abutted against the bag body, and A vehicle bag made of a resin material that is molded in a secondary injection process at a butting portion between the bag body and the lens unit, and is bonded to the bag body and the lens unit, and integrates the bag body and the lens unit. A method of manufacturing a heel body and a lens part in a body, wherein a movable surface formed with a concave surface for forming an outer surface of the heel body and a convex surface for forming an inner surface of the lens part To form the mold and the inner surface of the bag body A fixed mold formed with a convex mold surface and a concave mold surface for forming the outer surface of the lens part, and a vacuum vapor deposition apparatus for forming a reflective surface on the inner surface of the bag body, The movable mold can be moved toward and away from the fixed mold in a facing direction, and can be moved parallel to the fixed mold in a direction along its surface at a position spaced from the fixed mold. Configured, the fixed mold has a concave surface for accommodating the vacuum deposition apparatus,
Formed between a convex surface for forming the inner surface of the collar body and a concave surface for forming the outer surface of the lens portion, the vacuum evaporation apparatus is accommodated in the concave surface, and the movable mold is A concave surface for forming an outer surface of the heel body, a convex surface for forming an inner surface of the heel body, and an inner surface of the lens portion A primary abutting step for abutting a convex surface for forming the outer surface of the lens portion and a concave surface for forming the outer surface of the lens unit; a concave surface for forming the outer surface of the collar body; and an inner surface of the collar body The resin is injected between the convex surfaces for forming the inner surface and between the convex surface for forming the inner surface of the lens portion and the concave surface for forming the outer surface of the lens portion, respectively. Primary injection process for injection molding the main body and the lens part respectively Holding the bag body injection-molded in the primary injection process on the concave mold surface of the movable mold, holding the lens part injection-molded in the primary injection process on the concave mold surface of the fixed mold, The movable mold is moved in a direction away from the fixed mold, and then the concave mold surface of the movable mold holding the bag main body injection-molded in the primary injection step and the vacuum deposition of the fixed mold. A secondary abutting step of abutting the concave surface containing the device, a reflective surface forming step of vapor-depositing a reflective surface on the inner surface of the bag body by the vacuum vapor deposition device accommodated in the concave surface of the fixed mold, Holding the bag body on which the reflecting surface is formed in the reflecting surface forming step on the concave surface of the movable mold, and holding the lens part injection-molded in the primary injection step on the concave surface of the fixed mold , Separating the movable mold from the fixed mold Next, the fixed surface holding the concave mold surface of the movable mold that holds the bag main body on which the reflection surface is formed in the reflection surface forming step and the lens portion that is injection molded in the primary injection step. In a tertiary abutting step of abutting the concave mold surface of the mold, the butted portion of the concave mold surface of the movable mold holding the bag main body formed with the reflective surface and the concave mold surface of the fixed mold holding the lens portion, A secondary injection step of injection molding a resin material that is bonded to the collar body and the lens part and integrates the collar body and the lens part, and moves the movable mold away from the fixed mold. A vehicular casing comprising a step of taking out the main body and the lens unit integrated in the secondary injection step from the movable mold and the fixed mold. It is a manufacturing method.

Next, embodiments of the present invention will be described with reference to the drawings. In the drawing
1 is a movable mold (first mold), 2 is a fixed mold (second mold), and the movable mold 1 can be moved away from and in the opposite direction to the fixed mold 2 and fixed. Although it is configured to move in the direction along the surface (parallel movement) with respect to the fixed mold 2 in a state of being separated from the mold 2, the details of the moving mechanism are the techniques used in the conventional die slide injection. Is omitted because it can be adopted. Since the movement of the mold may be relative, the first mold may be fixed and the second mold may be moved, or of course, both may be moved. . Further, the movement is not limited to the parallel movement in the linear direction as long as the movement is in the direction along the surface, and may be a rotational movement around the axis.

The movable mold 1 is formed with a concave mold surface 1a for forming the outer surface of the bag main body 3 and a convex mold surface 1b for forming the inner surface of the lens part 4, respectively, while the fixed mold 2 Are formed with a convex surface 2a for forming the inner surface of the bag main body 3 and a concave surface 2b for forming the outer surface of the lens portion 4, respectively, and further accommodates a vacuum deposition apparatus 5 ( A concave surface 2c is formed for the interior), and the concave surface 2c is a convex surface 2a for forming the inner surface of the bag body 3.
And the concave surface 2 for forming the outer surface of the lens portion 4. The vacuum vapor deposition apparatus 5 is provided with a publicly known one, and as an outline, an intake passage 6 connected to a vacuum pump P,
A boat 7 for containing a metal (for example, aluminum or chromium) to be deposited and a heater 8 for heating the boat 7 are provided.

The housing 9 is a side blinker in the present embodiment, and includes a terminal 10, a bulb (light bulb) 1
1 includes a bag body 3 that is incorporated as a necessary part and is molded from a non-translucent resin material, and a lens portion 4 that is molded from a translucent (transparent) resin material. After molding the heel body 3 and the lens portion 4, the movable mold 1 is moved (die slide) to change the heel body 3,
The lens part 4 is abutted and the resin material 12 is secondarily injected to the abutting surface part to form the housing 9 integrally.

Next, the manufacturing method of the housing 9 is demonstrated using drawing. FIG. 2 (A) shows both molds 1,
2, mold surfaces 1 a and 2 a forming the heel body 3, mold surface 1 b forming the lens part 4,
The two molds face each other in a state of being separated from each other, and the movable mold 1 is moved to the fixed mold 2 side from the separated state, and the opposed mold surfaces are matched (primary matching process: FIG. 2 (B)). In this mold-matching state, primary injection is performed, and the main body 3 and the lens unit 4
Are injection-molded (primary injection step: see FIG. 2C).

Thereafter, as shown in FIG. 3 (A), the movable mold 1 moves in a direction away from the fixed mold 2. At this time, the main body 3 is supported on the movable mold 1 side (remaining), The mold is designed so that the lens portion 4 is supported (remains) on the fixed mold 2 side. Next, the movable mold 1 is moved in parallel so that the bag main body 3 faces the vacuum deposition apparatus 5 (see FIG. 3B), and then moves to the fixed mold 2 side to be in a mold matching state (secondary matching). Process: See FIG. 3C). In a state where the molds 1 and 2 are separated from each other before or after the parallel movement, a portion where vacuum deposition is not desired,
Here, the cover member 13 for covering the terminal 10 of the bag main body 3 and the insertion portion 3a of the valve 11 is incorporated (inserted) into the bag main body 3 (cover member assembling step). The cover member 13 is incorporated in the previous stage. In addition, the concave mold surface 2c that houses the vacuum deposition apparatus 5 is designed so as to cover the butting surface 3b with the lens portion 4 of the bag main body 3 so as not to be vacuum deposited.

When the mold body 3 and the vacuum vapor deposition apparatus 5 face each other in a mold-matching state, the air in the concave mold surface 2c is extracted from the intake passage 6 to be in a vacuum state, and is supplied to the boat 7 by the heated heater 8. The molten metal is vaporized, and the exposed inner surface of the bag body 3 is vacuum-deposited to form the reflecting surface 14 (reflecting surface forming step: see FIG. 4A). Next, after moving the movable mold 1 away from the fixed mold 2 (see FIG. 4B), the movable mold 1 is moved in parallel with respect to the fixed mold 2 so that the rod body 3 and the lens unit 4 face each other. (See FIG. 4C). Incidentally, before and after moving the movable mold 1 in parallel, a step of removing the covering member 13 and a step of incorporating the necessary terminals 10 and valves 11 can be performed. In this embodiment, the separation before the parallel movement is performed. The removal step and the incorporation step are executed at the step where the movement is finished.

After that, the movable mold 1 is moved to the fixed mold 2 side so that the main body 3 and the lens unit 4 are brought into contact with each other (
Tertiary butting process: see FIG. 5 (A)), the resin material 12 is secondarily injected to the butting surface of the collar body 3 and the lens part 4 (secondary injecting process: see FIG. 5 (B)), thereby The main body 3 and the lens unit 4 are integrated to form a main body 9 in which a reflecting surface 14 is formed. Then, the movable mold 1 is separated from the fixed mold 2 and the molded housing 9 is taken out (see FIG. 5C). After that, the movable mold 1 is moved as shown in FIG. The translation is made to the initial position, and this process is repeated thereafter.

In the embodiment of the present invention configured as described above, when manufacturing the casing 9, the primary injection molding process for forming the casing body 3 and the lens section 4, and the casing body 3 and the lens section 4 are combined. As a result of providing a reflection surface forming step for forming the reflection surface 14 on the inner surface of the bag main body 3 during the secondary injection step for integration, the bag main body once taken out of the mold as in the past 3 is formed, and after that, it is not necessary to take out and re-set the bag main body 3 as in the conventional case where it must be set in the mold again. A reflective surface can be formed on the bag main body 3 to improve work efficiency. Moreover, since the bag body 3 is not taken out and re-set, the reflective surface 14 is not touched with a finger to get a fingerprint or hit with an object, and the generation of defective products can be greatly reduced.

In addition, since the concave mold surface 2c in which the vacuum vapor deposition apparatus 5 is accommodated is formed in the second mold 2 that is a fixed mold, the vacuum vapor deposition apparatus 5 is provided on the movable mold 1 side. As a result, there is no problem that the molten metal in the boat 7 spills out.
Furthermore, in this case, the portion where the reflecting surface is not desired to be formed, that is, the terminal 10 and the bulb 11
If the reflective surface is formed with a metal film on the mounting portion 3a, the insulation is impaired and the circuit is short-circuited. Therefore, the reflective surface 14 is formed after the portion is closed by the plugging member 13. The housing 9 has no problem. Moreover, since the terminal 10 and the valve 11 are assembled after the blocking member 13 is removed after the reflecting surface 14 is formed, all manufacturing operations are smoothly performed in a series of die slide injection processes, and the efficiency is improved. Can be manufactured.

Moreover, the concave surface 2c for accommodation of the vapor deposition apparatus 5 formed in the fixed mold 2 is composed of the bowl body 3 and the lens portion 4.
Between the mold surfaces 2a and 2b for forming the movable mold 1 so that the movable mold 1 is moved from the primary injection process to the reflective surface forming process and movable from the reflective surface forming process to the secondary injection process. As a result of the movement direction of the mold 1 being the same direction, there is an advantage that the configuration of the die slide mechanism can be simplified.

Note that the present invention is not limited to the above-described embodiment, and as the reflecting surface forming means,
It is not limited to a vacuum evaporation apparatus, For example, the reflection surface formation apparatus generally known, such as the method by cathode sputtering, can be employ | adopted. In addition, a terminal or a valve can be retrofitted to the housing.

It is a longitudinal cross-sectional view of a side blinker. (A), (B), and (C) are process schematic diagrams until the primary injection. (A), (B), and (C) are process schematic diagrams up to the secondary matching. (A), (B), and (C) are process schematic diagrams until the bag main body and the lens portion face each other. (A), (B), and (C) are process schematics until a housing is taken out.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Movable metal mold | die 2 Fixed metal mold | die 2c Concave mold surface 3 燈 main body 4 Lens part 5 Vacuum evaporation apparatus 9 Housing | casing 10 Terminal 11 Valve | bulb 12 Resin material injected secondaryly 13 Cover member 14 Reflecting surface

Claims (2)

A light source;
The light source is incorporated, a reflective surface for reflecting light emitted from the light source is formed on the inner surface, and a bag main body molded in a primary injection process using a resin material,
A lens part that is molded in a primary injection process with a translucent resin material that transmits light emitted from the light source, and is abutted against the bag body;
A casing made of a resin material that is molded in a secondary injection process at a butting portion between the collar body and the lens part, is bonded to the collar body and the lens part, and integrates the collar body and the lens part. A manufacturing method comprising:
A movable mold in which a concave surface for forming the outer surface of the collar body and a convex surface for forming the inner surface of the lens unit are formed,
A stationary mold in which a convex surface for forming the inner surface of the collar body and a concave surface for forming the outer surface of the lens portion are formed, respectively.
Having a vapor deposition device for forming a reflective surface on the inner surface of the bag main body,
The movable mold is configured to be movable toward and away from the fixed mold,
The fixed mold has a concave surface for accommodating the vapor deposition apparatus, and the vapor deposition apparatus is accommodated in the concave mold surface.
The movable mold is moved with respect to the fixed mold to form a concave mold surface for forming the outer side surface of the collar body, a convex surface for forming the inner surface of the collar body, and the lens portion. A primary matching step of abutting a convex surface for forming the inner surface and a concave surface for forming the outer surface of the lens unit;
Between the concave surface for forming the outer surface of the collar body and the convex surface for forming the inner surface of the collar body, and the convex surface and the lens section for forming the inner surface of the lens section A primary injection step of injecting resin between the concave surfaces for forming the outer surface of each of the above and injection-molding the bag body and the lens part,
Holding the bag body injection-molded in the primary injection process on the concave mold surface of the movable mold, holding the lens part injection-molded in the primary injection process on the concave mold surface of the fixed mold, The movable mold is moved in a direction away from the fixed mold, and then the concave mold surface of the movable mold and the vapor deposition apparatus for the fixed mold holding the bag main body injection-molded in the primary injection step. A secondary matching process to match the concave surface containing
A reflective surface forming step of vapor-depositing a reflective surface on an inner surface of the bag body by the vapor deposition device housed in the concave mold surface of the fixed mold;
Holding the bag body on which the reflecting surface is formed in the reflecting surface forming step on the concave surface of the movable mold, and holding the lens part injection-molded in the primary injection step on the concave surface of the fixed mold The movable mold is moved in a direction away from the fixed mold, and then the concave mold surface of the movable mold and the primary injection holding the bag main body formed with the reflective surface in the reflective surface forming step. A tertiary matching step of matching the concave mold surface of the fixed mold holding the lens part injection-molded in the process;
The movable mold is moved away from the fixed mold, and the bag body and the lens unit integrated in the secondary injection process are taken out of the movable mold and the fixed mold. A method for producing a housing, comprising: a take-out step. A light source;
A terminal connected to the light source;
The light source and the terminal are incorporated, a reflective surface that reflects light emitted from the light source is formed on the inner surface, and a bag main body molded in a primary injection process using an opaque resin material,
A lens part that is molded in a primary injection process with a translucent resin material that transmits light emitted from the light source, and is abutted against the bag body;
A vehicular body made of a resin material that is molded in a secondary injection process at a butting portion between the heel body and the lens portion, and is bonded to the heel body and the lens portion, and integrates the heel body and the lens portion. A method for manufacturing a lens body and a lens part in a lens body,
A movable mold in which a concave surface for forming the outer surface of the collar body and a convex surface for forming the inner surface of the lens unit are formed,
A stationary mold in which a convex surface for forming the inner surface of the collar body and a concave surface for forming the outer surface of the lens portion are formed, respectively.
A vacuum vapor deposition device for forming a reflective surface on the inner surface of the bag body,
The movable mold can be moved toward and away from the fixed mold in a facing direction, and can be moved parallel to the fixed mold in a direction along its surface at a position spaced from the fixed mold. Configured,
In the fixed mold, a concave surface for accommodating the vacuum deposition apparatus is formed between a convex surface for forming the inner surface of the bag body and a concave surface for forming the outer surface of the lens part, The vacuum deposition apparatus is accommodated in the concave surface,
The movable mold is moved in a direction opposite to the fixed mold to form a concave mold surface for forming an outer surface of the heel body, a convex surface for forming an inner surface of the heel body, and A primary abutting step of abutting a convex surface for forming the inner surface of the lens portion and a concave surface for forming the outer surface of the lens portion;
Between the concave surface for forming the outer surface of the collar body and the convex surface for forming the inner surface of the collar body, and the convex surface and the lens section for forming the inner surface of the lens section A primary injection step of injecting resin between the concave surfaces for forming the outer surface of each of the above and injection-molding the bag body and the lens part,
Holding the bag body injection-molded in the primary injection process on the concave mold surface of the movable mold, holding the lens part injection-molded in the primary injection process on the concave mold surface of the fixed mold, The movable mold is moved in a direction away from the fixed mold, and then the concave mold surface of the movable mold holding the bag main body injection-molded in the primary injection step and the vacuum deposition of the fixed mold. A secondary matching process to match the concave surface containing the device,
A reflective surface forming step of vapor-depositing a reflective surface on the inner surface of the bag body by the vacuum vapor deposition device housed in the concave mold surface of the fixed mold;
Holding the bag body on which the reflecting surface is formed in the reflecting surface forming step on the concave surface of the movable mold, and holding the lens part injection-molded in the primary injection step on the concave surface of the fixed mold The movable mold is moved in a direction away from the fixed mold, and then the concave mold surface of the movable mold and the primary injection holding the bag main body formed with the reflective surface in the reflective surface forming step. A tertiary matching step of matching the concave mold surface of the fixed mold holding the lens part injection-molded in the process;
At the abutting portion between the concave mold surface of the movable mold holding the bag main body formed with a reflecting surface and the concave mold surface of the fixed mold holding the lens unit, the bag main body and the lens unit are bonded to each other. A secondary injection step of injection molding a resin material that integrates the main body and the lens portion;
The movable mold is moved away from the fixed mold, and the bag body and the lens unit integrated in the secondary injection process are taken out from the movable mold and the fixed mold. The manufacturing method of the housing for vehicles characterized by including the process.

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