JP2008052922A - Wire heater transferring tool in vehicular lamp - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve the following problem: no consideration has been taken to surely and inexpensively paste a film to a front lens in a short cycle in a conventional vehicular lamp. <P>SOLUTION: This wire heater transferring tool has a receiving tool 27 to receive a lamp lens 4, a pressurizing tool 28 holding a wire heater 5 through a separator 21 to transfer the wire heater 5 to the lamp lens 4 received by the receiving tool 27 by pressurizing it. A head 30 to pressurize the wire heater 5 onto the lamp lens 4 through the separator 21 is provided in the pressurizing tool 28, and the head 30 is formed from a raw material having flexibility. As a result, the wire heater 5 can be surely and inexpensively pasted to the lamp lens 4 in a short cycle. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a vehicular lamp in which a lamp lens has a snow melting (deicing, anti-fogging) structure, that is, a vehicular lamp having a lamp lens to which a line heater is transferred, and a jig for transferring the line heater to the lamp lens. It is about.

  This type of vehicular lamp is conventionally known (for example, Patent Document 1). Hereinafter, a conventional vehicle lamp will be described. A conventional vehicular lamp includes a front lens and a wiring board heater (a conductive foil pattern printed on a base film) joined and integrated to the front lens with an adhesive.

  Hereinafter, the operation of the conventional vehicle lamp will be described. When power is supplied to the conductive foil pattern of the wiring board heater, the conductive foil pattern generates heat, and the heat melts or removes snow, ice, and cloudiness adhering to the front lens. As a result, loss of light irradiated from the front lens to the outside can be prevented. In particular, in a vehicular lamp using a light source having a low temperature of light emitted from a front lens as a light source, for example, a semiconductor light source such as an LED or a discharge lamp such as an HID, as compared with a halogen bulb or an incandescent bulb. Is effective.

  In this type of vehicle lamp, when the film of the wiring board heater is bonded to the front lens with an adhesive, it is important to bond the film to the front lens reliably, inexpensively, and with a short tact. However, in the conventional vehicular lamp, when the film of the wiring board heater is bonded to the front lens with an adhesive, no consideration is given to bonding the film to the front lens reliably, inexpensively, and with a short tact.

Japanese Patent Laid-Open No. 10-109587

  The problem to be solved by the present invention is that, in the conventional vehicular lamp, when the film of the wiring board heater is bonded to the front lens with an adhesive, the film is reliably and inexpensively and has a short tact time. It is in the point which is not considered about adhesion | attachment.

  The present invention (the invention according to claim 1) is a pressure receiving tool that receives a lamp lens, and a pressure that holds the wire heater via a separator and pressurizes and transfers the wire heater to the lamp lens received by the receiving jig. A head for holding the wire heater via a separator and pressurizing the lamp lens is provided on the pressure jig, and the head is made of a flexible material.

  Further, the present invention (the invention according to claim 2) is characterized in that a holding portion for positioning and temporarily fixing the separator is provided in the head.

  Furthermore, the present invention (the invention according to claim 3) is characterized in that a portion that is not transferred to the lamp lens is provided in the wire heater, and a groove that avoids the portion is provided in a portion of the head corresponding to the portion. To do.

  Furthermore, in the present invention (the invention according to claim 4), the surface of the lamp lens for transferring the line heater and the pressure surface of the head are curved, and the radius of curvature of the pressure surface of the head is the same as that of the transfer surface of the lamp lens. It is characterized by being smaller than the radius of curvature.

  The line heater transfer jig in the vehicular lamp according to the present invention (the invention according to claim 1) uses a receiving jig and a pressure jig to press and transfer the line heater to the lamp lens. For this reason, the wire heater transfer jig in the vehicular lamp according to the present invention (the invention according to claim 1) has a pressurizing direction that is greater than that of means for transferring the line heater to the lamp lens using a roller or a spatula. Since only one direction is required, the structure of the pressurizing mechanism is simplified, and the manufacturing cost is reduced accordingly. Moreover, the wire heater transfer jig in the vehicular lamp of the present invention (the invention according to claim 1) can press and transfer almost all the portions of the line heater to the lamp lens almost simultaneously by applying pressure in one direction. Therefore, the transfer can be completed in a short time, and the tact can be shortened. In addition, the wire heater transfer jig in the vehicular lamp according to the present invention (the invention according to claim 1) is configured such that the head for pressing the line heater against the lamp lens is made of a flexible material. By the pressure and elastic deformation, the line heater can be reliably transferred to the lamp lens (that is, transferred in close contact with the lamp lens).

  The line heater transfer jig in the vehicular lamp according to the present invention (the invention according to claim 2) can position and temporarily fix the separator to the head by a holding portion provided on the head. For this reason, the vehicular lamp of the present invention (the invention according to claim 2) can easily set the separator and the wire heater to the pressure jig via the separator. In addition, the wire heater transfer jig in the vehicular lamp according to the present invention (the invention according to claim 2) can be set by positioning the line heater on the pressure jig via the separator and the separator. The line heater can be accurately transferred to a predetermined position.

  Furthermore, the wire heater transfer jig in the vehicular lamp according to the present invention (invention according to claim 3) is configured such that the portion of the line heater that is not to be transferred to the lamp lens is positioned in the groove of the head so that the lamp lens is attached to the line heater. Since it is possible to arbitrarily set a portion that is not desired to be transferred, high-quality transfer can be obtained depending on the degree of freedom in setting the transfer portion and non-transfer portion of the line heater. For example, by providing a power supply unit with a width larger than the width of the line heater in the line heater, and when the transfer of the power supply unit is difficult compared to the transfer of the line heater, this power supply unit is positioned in the groove of the head. Since the line heater can be transferred to the lamp lens without transferring the power feeding portion to the lamp lens, high-quality transfer of the line heater can be obtained.

  Furthermore, the wire heater transfer jig in the vehicular lamp according to the present invention (the invention according to claim 4) is held on the pressure surface of the head having a small curvature radius via a separator by means for solving the above-mentioned problems. When the line heater is transferred onto the transfer surface of the lamp lens having a large radius of curvature, the line heater is sequentially pressed and transferred from the apex of the line heater toward the periphery thereof, so that the line heater is less likely to bend and wrinkle. A higher quality transfer of the heater is obtained.

  Hereinafter, two examples of embodiments of the line heater transfer jig in the vehicular lamp according to the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited to the embodiments.

  FIGS. 1-13 shows Example 1 of the wire heater transfer jig in the vehicle lamp concerning this invention. Hereinafter, a lamp lens in which the line heater is transferred by the line heater transfer jig according to the first embodiment, and the vehicular lamp including the lamp lens will be described.

  The vehicular lamps are automotive headlamps 1L and 1R that irradiate a predetermined light distribution pattern, for example, a light distribution pattern for passing. The headlamps 1L and 1R are respectively provided on the left and right sides of the front portion of the automobile C as shown in FIG. Hereinafter, the left headlamp 1L will be described. The right headlamp 1R is substantially opposite to the left and right headlamp 1L.

  As shown in FIGS. 2 and 4, the headlamp 1 </ b> L includes five lamp units 2, a lamp housing 3, a lamp lens 4, a line heater 5, and a power feeding unit 6. A lamp chamber 7 is defined by the lamp housing 3 and the lamp lens 4. In the lamp chamber 7, the five lamp units 2 are arranged in two upper and lower stages (in this example, three in the upper stage and two in the lower stage).

  The lamp unit 2 constitutes a light irradiation unit that irradiates light to the outside through the lamp lens 4. The lamp unit 2 irradiates (radiates and emits) a predetermined light distribution pattern, in this example, a light distribution pattern for passing. As shown in FIG. 3, the lamp unit 2 is a projector type and has a unit structure. The lamp unit 2 includes an upper reflector 8 and a lower reflector 9, a reflecting surface 10 and a shade 11, a semiconductor light source 12, a projection lens (convex lens, condenser lens) 13, and a heat sink member 14. ing.

  As shown in FIG. 2, the lamp unit 2 is attached to the lamp housing 3 via a holder member 15. The lamp housing 3 is provided with a heat sink member 16. The heat sink member 16 on the lamp housing 3 side and the heat sink member 14 on the lamp unit 2 side are connected via the holder member 15 and the lamp housing 3.

  As the semiconductor-type light source 12, for example, a self-luminous semiconductor-type light source (LED in this embodiment 1) such as LED and EL (organic EL) is used. For this reason, although heat is generated in the semiconductor light source 12 itself, almost no heat is generated in the light from the semiconductor light source 12. As a result, snow, ice, or cloudiness tends to adhere to the lamp lens 4.

  The lamp lens 4 is a substantially transparent lens, and is an outer cover (outer lens) that is a so-called light-transmitting cover. In this example, the lamp lens 4 is molded from a synthetic resin such as PC (polycarbonate). Further, as shown in FIG. 2, the lamp lens 4 is slanted (inclined) from the rear to the front in the longitudinal section (vertical section) from the top to the bottom. Further, the lamp lens 4 has a concave cross section, and is integrated with a front part (or front part) 33 through which light emitted from the lamp unit 2 passes, and from the entire periphery from the front part 33 to the rear. And a side wall portion 34 extending to the wall. A corner portion is formed between the front portion 33 and the side wall portion 34. The inner surface of the front portion 33 of the lamp lens 4, that is, the transfer surface on which the line heater 5 is provided by transfer, forms a concave curved surface as shown in FIG. When the material of the lamp lens 4 is PC, the heat resistant temperature of the lamp lens 4 is about 130 ° C.

  The line heater 5 is a transfer type line heater, and is used on the inner surface (transfer surface) of the front portion 33 of the lamp lens 4 by using the line heater transfer jig in the vehicular lamp according to the first embodiment. It is provided by transcription. As shown in FIGS. 5, 6 and 11, the line heater 5 provided on the inner surface of the front portion 33 of the lamp lens 4 includes a base film 17, an adhesive 18, and a heater conductive material. The conductive paste 19 as a conductive member and a resist 20 are included. The line heater 5 is preferably light transmissive.

  The base film 17 is made of a transparent synthetic resin film such as PET (polyethylene terephthalate). The adhesive 18 is provided on one surface of the base film 17.

  On the other surface of the base film 17, the conductive paste 19 is formed in a line pattern. In this example, the line pattern of the conductive paste 19 includes four horizontal lines that are substantially parallel to each other, two vertical lines on the left side, and one vertical line on the right side, as shown in FIG. The line pattern is zigzag continuous from side to side. Two vertical lines from the right side of the top two horizontal lines are continuously formed as terminal portions. The conductive paste 19 is a conductive ink, and in this example, is made of a metal paste such as a silver paste, a gold paste, a copper paste, or an aluminum paste. The conductive paste 19 generates heat due to the electric resistance of the conductive paste when a current is supplied. When the electric resistance value is high, the generated heat amount is low, and when the electric resistance value is low, the generated heat amount is low. high.

  The resist 20 is provided on the other surface of the base film 17 so as to cover the conductive paste 19. The resist 20 electrically insulates the conductive paste 19 and protects it from external impacts. That is, the resist 20 is a surface protective coat of the conductive paste 19. In this example, the resist 20 is made of urethane or acrylic adhesive.

  At least one of the base film 17 and the resist 20 is colored. That is, a colored layer is provided on one side or the other side of the base film 17. Alternatively, the base film 17 itself or the resist 20 itself is colored.

  The base film 17 (including the adhesive 18 in this example) is cut into a pattern following the line pattern of the conductive paste 19. The width W of the cut base film 17 is about 0.5 mm in this example, and is substantially the same as the width of the resist 20. Then, using the line heater transfer jig according to Example 1, as shown in FIG. 11, after the base film 17 is cut, the bonding is performed via the separator 21 disposed on the resist 20 side. The agent 18 is bonded to the inner surface of the front portion 33 of the lamp lens 4 to transfer the conductive paste 19 in a line pattern onto the inner surface of the front portion 33 of the lamp lens 4. Thereby, the line heater 5 is provided on the inner surface of the front portion 33 of the lamp lens 4 by transfer.

  As shown in FIG. 11, the separator 21 is peeled off from the resist 20 side after the conductive paste 19 having a line pattern is transferred to the inner surface of the front portion 33 of the lamp lens 4. The separator 21 can be mounted with the line heater 5 having a pattern shape following the line pattern of the conductive paste 19, and can be transferred to the inner surface of the front portion 33 of the lamp lens 4. The sheet has a size and shape as much as possible. The separator 21 uses a flexible material, in this example, a rubber-based material such as urethane so that it can follow the curved surface of the inner surface of the front portion 33 of the lamp lens 4.

  As shown in FIGS. 4, 8, and 9, the wire heater 5 is provided with the power feeding unit 6. The power feeding unit 6 supplies current to the wire heater 5. Similarly to the wire heater 5, the power feeding unit 6 is provided on the inner surface (the lamp chamber 7 side) of the front surface portion 33 and the side wall portion 34 of the lamp lens 4. In addition, the power feeding unit 6 is provided at a place where the influence on the design of the lamp lens 4 is small, that is, in the vicinity of a corner between the front portion 33 and the side wall portion 34 of the lamp lens 4. The power feeding unit 6 includes a film 24, a conductive paste 25 as a power feeding conductive member, and a connector 26.

  The film 24 extends from the base film 17 of the line heater 5. Similar to the base film 17, the film 24 is made of a transparent synthetic resin film such as PET (polyethylene terephthalate). The width W1 of the film 24 is about 10 mm in this example with respect to the width W (about 0.5 mm) of the base film 17. Further, the length of the film 24 is such a length as to reach the side wall portion 34 of the lamp lens 4 from the line heater 5. One surface of the front end (right end portion) of the film 24 is adhered and fixed to the inner surface of the side wall portion 34 of the lamp lens 4 by an adhesive 32 such as a double-sided tape (double-sided adhesive tape) having sufficient durability. Yes. 4, 8, and 9, the left end portion of the film 24 is illustrated on the left side of the line heater 5. The line heater 5 is located substantially on the same line.

  The conductive paste 25 for feeding is formed in a line pattern on the other surface of the film 24 and one end thereof is electrically connected to a terminal portion of the conductive paste 19 for heater. The conductive paste 25 for power feeding is a conductive ink, similar to the conductive paste 19 for heaters. In this example, the conductive paste 25 is made of a metal paste such as a silver paste, a gold paste, a copper paste, or an aluminum paste. . The power supply conductive paste 25 is thicker (thicker and wider) than the heater conductive paste 19, and has a smaller electrical resistance than the heater conductive paste 19. At the front end of the film 24, the other end of the conductive paste 25 for power feeding is integrally provided with a wide portion 49 for electrodes or power feeding.

  A resist (not shown) may be provided on the other surface of the film 24 so as to cover the conductive paste 25 for power feeding. The resist, like the resist 20, electrically insulates the conductive paste 25 for power supply and protects it from external impacts, that is, the surface of the conductive paste 25 for power supply. It is a protective coat. Like the resist 20, the resist is made of a urethane-based or acrylic adhesive in this example.

  Further, at least one of the film 24 and the resist is colored. That is, a colored layer is provided on one side or the other side of the film 24. Alternatively, the film 24 itself or the resist itself is colored.

  The connector 26 is electrically connected to the wide portion 49 at the other end of the conductive paste 25 for power feeding and is fixed to the tip of the film 24. The connector 26 is fixed to the inner surface of the side wall 34 of the lamp lens 4 together with the film 24.

  For example, the surface mount type connector 26 is fixed to one end of the film 24 of the power feeding unit 6 by a conductive adhesive (not shown) and a sealing agent (not shown) and is electrically conductive. The paste 25 is electrically connected to the wide portion 49. The surface mount type connector 26 transfers the wire heater 5 to the front portion 33 of the lamp lens 4, and then attaches the other surface of the film 24 to the front surface 33 of the lamp lens 4 with the adhesive 32. It is fixed to the inner surface of the side wall 34 of the lamp lens 4 together with the film 24 by bonding and fixing to the inner surface of the side wall 34.

  Further, the spring pressure type connector 26 is provided with a spring (not shown) on one surface, and the wire heater 5 is transferred to the front portion 33 of the lamp lens 4, and After one surface of the film 24 is adhered and fixed to the inner surface of the side wall 34 of the lamp lens 4 with the adhesive 32, a double-sided adhesive tape ( (Not shown) is fixed to the other surface of the film 24 and electrically connected to the wide portion 49 of the conductive paste 25. Thus, the spring pressure type connector 26 is bonded and fixed to the inner surface of the side wall 34 of the lamp lens 4 together with the film 24.

  At this time, as shown in FIG. 7, both ends of the film 24 of the power feeding unit 6 are connected to the inner surface of the front part 33 of the lamp lens 4 and the side wall part 34 via the wire heater 5 and the connector 26. Are fixed to the inner surface of each. Further, an intermediate portion of the film 24 of the power feeding unit 6 is bent along a corner portion between the front portion 33 and the side wall portion 34 of the lamp lens 4. As a result, the film 24 of the power feeding unit 6 is securely fixed in a state along the corner of the lamp lens 4 by an elastic restoring force (see a solid line arrow A in FIG. 7). As a result, the power feeding unit 6 is securely fixed to the inner surfaces of the front surface part 33 and the side wall part 34 of the lamp lens 4.

  One end of two heater-side harnesses 35 is electrically connected to the connector 26. A heater-side connector 37 is attached and electrically connected to the other end of the two heater-side harnesses 35. As shown in FIG. 7, the two heater-side harnesses 35 are provided with a waterproof structure provided in the side wall portion 34 of the lamp lens 4, in this example, via a rubber waterproof grommet 38, for example. The lamp chamber 7 is drawn out of the lamp chamber 7. Further, as shown in FIG. 13, the two heater-side harnesses 35 are provided with a waterproof structure provided in the lamp housing 3, in this example, via a waterproof grommet 38 made of rubber, for example. It may be drawn out of the lamp chamber 7 from the inside.

  In FIG. 7, reference numeral “39” denotes two power supply side harnesses whose one ends are electrically connected to the power supply. A power supply side connector 40 is attached to and electrically connected to the other ends of the two power supply side harnesses 39. The heater side connector 37 is detachably coupled to the power source side connector 40. As a result, the line heater 5 is electrically connected to a power source via the power feeding unit 6.

  The power supply side connector 40 is fixed outside the lamp chamber 7 of the lamp housing 3. As a result, a part of the heater side harness 35, the heater side connector 37, the power source side connector 40, and the power source side harness 39 are located outside the lamp chamber 7 of the lamp housing 3.

  Other vehicle parts (for example, other vehicle lamps, bumpers, decorative parts, etc.) 41 are provided adjacent to the outside of the headlamp 1L. A part of the heater-side harness 35 located outside the lamp chamber 7 of the lamp housing 3, the heater-side connector 37, the power-side connector 40, and the power-side harness 39 are the same as those of the vehicular lamp according to the first embodiment. Since it is located between the headlamp 1L and the other vehicle parts 41, it cannot be seen from the outside, and there is no problem in appearance.

  The line heater 5 is connected to a manual switch (not shown) or an automatic switch (not shown) via the power supply unit 6. The manual switch manually turns on / off the current supply to the line heater 5. The automatic switch automatically turns on / off the current supply to the line heater 5.

  The automatic switch includes a control unit such as an ECU and a detection unit such as a temperature sensor or an optical sensor. The detection unit detects the ambient environment of the vehicle C, for example, the temperature outside the vehicle C, the light emitted from the lamp lens 4, and outputs the detection signal to the control unit. The control unit determines whether or not snow, ice, or cloudiness is attached to the lamp lens 4 based on a detection signal from the detection unit, or snow, ice, or cloudy is attached to the lamp lens 4. Judge whether the temperature is about. When the controller determines that the lamp lens 4 has snow, ice, cloudy, or the like, or the temperature of the lamp lens 4 has snow, ice, cloudy, or the like, A current is supplied to the wire heater 5 through the power feeding unit 6. On the other hand, when the control unit determines that the lamp lens 4 is not covered with snow, ice, or cloudy or the temperature is not such that snow, ice, or cloudy is attached to the lamp lens 4, the power supply is performed. The current supply to the wire heater 5 is cut off via the section 6.

  One terminal portion of the wire heater 5 is provided with a temperature control unit (not shown). The temperature control unit controls the heat generation temperature of the conductive paste 19. For example, a PTC thermistor is used as the temperature control unit. This PTC thermistor has a characteristic that its resistance value increases as the temperature rises, and current does not flow when it reaches a predetermined resistance value. For example, when the material of the lamp lens 4 is PC, the heat-resistant temperature of the lamp lens 4 is about 130 ° C. Therefore, when the heat generation temperature of the conductive paste 19 reaches about 60 ° C., the current flows. A PTC thermistor having a resistance characteristic that does not flow is used as the temperature controller.

  Hereinafter, the configuration of the line heater transfer jig in the vehicular lamp according to the first embodiment will be described.

  The line heater transfer jig in the vehicular lamp according to the first embodiment is a jig that transfers the line heater 5 to the lamp lens 4, and includes a receiving jig 27 and a pressure jig 28.

  The receiving jig 27 receives the lamp lens 4, and a concave portion 29 in which the lamp lens 4 is housed and held is provided on one surface of the receiving jig 27. That is, the lamp lens 4 is detachably accommodated in the recess 29 of the receiving jig 27, whereby the outer surface of the lamp lens 4 is held on the wall surface of the recess 29 of the receiving jig 27.

  The pressure jig 28 holds the wire heater 5 via the separator 21 and presses and transfers the line heater 5 to the lamp lens 4 received by the receiving jig 27. . The pressure jig 28 has a head 30, a connecting member 31 fixed to one surface of the head 30, and the head 30 in one direction through the connecting member 31 (in FIGS. 9, 10, and 12). And a pressurizing mechanism (not shown) for applying pressure to the lamp lens 4 held in the concave portion 29 of the receiving jig 27 by moving in the direction of the white arrow).

  The head 30 holds the wire heater 5 via the separator 21 and pressurizes the lamp lens 4 and is made of a flexible material such as urethane rubber or elastomer resin. The outer surface of the other surface of the head 30 is slightly smaller than the inner surface of the front portion 33 of the lamp lens 4.

  The other surface of the head 30 is a pressure surface that forms a convex curved surface. The pressure surface of the head 30 is provided with a plurality of small cylindrical pins (ribs) 36 as a holding portion for positioning and temporarily fixing the separator 21, in this example, four. On the other hand, the separator 21 is provided with a small circular through hole 42 into which the pin 36 is inserted. When the pin 36 of the head 30 is inserted into the through hole 42 of the separator 21, the separator 21 is positioned and temporarily fixed to the head 30.

  The pins 36 and the through holes 42 are provided at locations away from the wire heater 5 and the power feeding unit 6. Further, the side surface of the pin 36 may be a tapered surface with a tapered tip to facilitate fitting with the through hole 42. Further, the length of the pin 36 is such that when the wire heater 5 is pressure-transferred onto the inner surface of the front surface portion 33 of the lamp lens 4 by the receiving jig 27 and the pressing jig 28, The length is such that the tip does not hit the inner surface of the front portion 33 of the lamp lens 4. Alternatively, the pin 36 is held by a spring, and when the pin 36 hits the lamp lens 4, the pin 36 moves backward against the spring force of the spring, and the pin 36 moves away from the lamp lens 4. It is good also as a structure which returns to the original state with the spring force of a spring.

  The head 30 is provided with a groove 43. The groove 43 is provided from the pressure surface to the side surface of the head 30. The groove 43 is provided in the head 30 at a location corresponding to the power feeding unit 6 of the wire heater 5 held via the separator 21. The power feeding unit 6 is a portion that does not need to be transferred to the lamp lens 4 when the line heater 5 is transferred to the lamp lens 4. As described above, the groove 43 is for avoiding the feeding portion 6 that does not need to be transferred to the lamp lens 4 from being transferred to the lamp lens 4 when the line heater 5 is transferred to the lamp lens 4. Is.

  Furthermore, the inner surface of the front portion 33 that transfers the line heater 5 of the lamp lens 4 and the pressurization surface of the head 30 each have an uneven curved surface. The radius of curvature R1 of the pressure surface of the head 30 is smaller than the radius of curvature R2 of the inner surface (transfer surface) of the front portion 33 of the lamp lens 4. Nearly the center of the pressing surface of the convex curved surface of the head 30 has a vertex.

  Hereinafter, the manufacturing process of the line heater 5 (the power feeding unit 6) to be transferred to the lamp lens 4 of the headlamps 1L and 1R of the vehicle lamp, and the line heater transfer jig according to the first embodiment, A transfer process for transferring the line heater 5 to the lamp lens 4 will be described with reference to FIGS.

  First, the adhesive (adhesive layer) 18 is provided on one surface of the film corresponding to the base film 17, and a release sheet 22 such as a release film or release paper is attached to the adhesive 18 so as to be peeled off. The sheet member 23 is manufactured (see FIG. 11A). The sheet member 23 has such a size that the line heater 5 having a pattern shape following the line pattern of the conductive paste 19 can be formed. Further, the adhesive 18 is not provided on the film 24 in the film, that is, on one surface (lower surface) of the film 24 extending from the base film 17.

  Next, the conductive paste 19 for the heater and the power supply are applied to the other surface (upper surface) of the base film 17 of the sheet member 23 and the other surface (upper surface) of the film 24 extending from the base film 17. For example, the conductive paste 25 is printed by a method such as screen printing or hot stamp printing to form a line pattern (see FIG. 11B).

  Subsequently, the resist (insulating layer / protective film) 20 is printed on the other surface (upper surface) of the base film 17 of the sheet member 23 by a method such as screen printing or hot stamp printing. It is provided so as to cover the paste 19 (see FIG. 11C). At this time, the resist (insulating layer / protective film) is simultaneously printed on the other surface (upper surface) of the film 24 by a method such as screen printing or hot stamp printing, so that the conductive paste for feeding is supplied. 25 may be provided to cover 25.

  Then, the base film 17 and the adhesive 18 of the sheet member 23 are cut in a pattern following the line pattern of the conductive paste 19 by, for example, punching (die cutting) processing (see FIG. 11D). ). That is, a mold cutter (not shown) is pushed into the base film 17 and the adhesive 18 from the resist 20 side, and is stopped at the boundary between the adhesive 18 and the release sheet 22, and the base film 17 and the adhesive are bonded. The agent 18 is cut. In addition, in FIG.11 (C), the cut location of the said base film 17 and the said adhesive agent 18 is shown with the continuous line CL. The cutter is separated from the sheet member 23 and, of the cut base film 17 and the adhesive 18, an excess portion other than a pattern portion following the line pattern of the conductive paste 19 is removed from the release sheet 22. Excluded from. At this time, the film 24 is also simultaneously cut into a predetermined width W1 and a predetermined length by the same type of cutter.

  Thereby, as shown in FIG. 11 (D), the release sheet 22 of the sheet member 23 that has not been cut, the base film 17 that has been cut in a pattern that follows the line pattern of the conductive paste 19, and the The adhesive 18, the conductive paste 19 having a line pattern, and the resist 20 provided in a pattern following the line pattern of the conductive paste 19 are left. In this example, the cut width W of the base film 17 and the adhesive 18 is substantially the same as the width of the resist 20, and the width at which the resist 20 can cover the conductive paste 19, that is, the The resist 20 has a width capable of sealing and electrically insulating the conductive paste 19 and protecting it from external impacts. The cut width of the base film 17 is not limited to the cut width W.

  Then, after the base film 17 and the adhesive 18 of the sheet member 23 are cut with a pattern that follows the line pattern of the conductive paste 19, the separator 21 is disposed on the resist 20 side (FIG. 11E). )reference). As a result, the release sheet 22 of the sheet member 23 that has not been cut, the base film 17 and the adhesive 18 that have been cut in a pattern that follows the line pattern of the conductive paste 19, and the conductive pattern of the line pattern. The conductive paste 19 and the resist 20 provided in a pattern following the line pattern of the conductive paste 19 are placed on the separator 21 with the resist 20 side down. As a result, the line heater 5 (the power feeding unit 6) of the unit is manufactured. The unit includes the line heater 5 composed of the base film 17, the adhesive 18, the conductive paste 19, and the resist 20, and the release sheet 22 of the separator 21 and the sheet member 23. It will be.

  Then, the wire heater 5 and the power feeding unit 6 of the unit manufactured as described above are held on the head 30 of the pressure jig 28 via the separator 21 (see FIG. 9, see FIG. 9). 9 does not show the release sheet 22). That is, the through hole 42 of the separator 21 is fitted into the pin 36 of the pressure jig 28. Then, the line heater 5 is detachably held on the convex pressure surface of the head 30 via the separator 21. The power feeding unit 6 is located in the groove 43 of the head 30.

  On the other hand, the lamp lens 4 is housed and held in the recess 29 of the receiving jig 27 (see FIG. 10). At the same time or before and after that, the release sheet 22 of the unit is peeled off (see FIG. 11F). Subsequently, by driving the pressurizing mechanism of the pressurizing jig 28, the head 30 of the pressurizing jig 28 moves in one direction through the connecting member 31 (white in FIGS. 9, 10, and 12). The pressure is applied to the lamp lens 4 held in the recess 29 of the receiving jig 27 (see FIG. 12).

  Then, the adhesive 18 of the wire heater 5 held by the head 30 is bonded to the inner surface of the front portion 33 of the lamp lens 4 held by the receiving jig 27 via the separator 21. As a result, the conductive paste 19 of the wire heater 5 is transferred to the inner surface of the front portion 33 of the lamp lens 4 (see FIG. 11G). At this time, since the power feeding unit 6 is located in the groove 43 of the head 30, it can be avoided from being transferred to the lamp lens 4.

  Then, by reversely driving the pressurizing mechanism of the pressurizing jig 28, the pressurizing jig 28 moves in the reverse direction and moves away from the receiving jig 27. At this time, if the separator 21 is held by the head 30 through the fitting of the pin 36 and the through hole 42, the separator 21 is peeled off from the resist 20. If the separator 21 is attached to the resist 20 side, the separator 21 is peeled off from the resist 20. As a result, as shown in FIGS. 4 to 7, the line heater 5 is transferred to the inner surface of the front portion 33 of the lamp lens 4.

  Hereinafter, the lamp lens 4 to which the line heater 5 is transferred by the line heater transfer jig according to the first embodiment, and the operation of the vehicle lamp including the lamp lens 4, that is, the head lamps 1L and 1R for automobiles will be described. Will be described.

  The semiconductor light sources 12 of the five lamp units 2 are turned on. Then, the light from the semiconductor-type light sources 12 of the five lamp units 2 is reflected by the reflecting surface 10 of the upper reflector 8, and a part of the reflected light is cut off by the shade 11 of the lower reflector 9, and the remaining reflections Light passes through the projection lens 13 and the front portion 33 of the lamp lens 4 and is irradiated with a predetermined light distribution pattern having a cut-off line outside, that is, a light distribution pattern for passing. The cut-off line of the light distribution pattern for passing is formed by the edge of the shade 11. In addition, by providing the shade 11 with the reflection surface, it is possible to use the reflection light reflected from the reflection surface 10 and reflected by the reflection surface of the shade 11.

  Here, since the line heater 5 provided for transfer on the front portion 33 of the lamp lens 4 has a linear pattern, when light passes through the front portion 33 of the lamp lens 4, the loss or distribution of light is reduced. The influence of light can be minimized. Moreover, since the lamp unit 2 using the semiconductor-type light source 12 as a light source is used, the width of light emitted from the lamp unit 2 is small. For this reason, the light loss, the influence of light distribution, etc. can be further prevented by passing light having a small width between the linear patterns of the line heater 5.

  And since almost no heat is generated in the light from the semiconductor-type light source 12, snow, ice, or cloudiness tends to adhere to the lamp lens 4. In this case, a current is supplied to the line heater 5 provided by transfer on the front portion 33 of the lamp lens 4 by a manual switch or an automatic switch.

  When a current is supplied to the line heater 5, the line heater 5 generates heat due to the electric resistance of the line heater 5. The heat generated by the wire heater 5 warms the lamp lens 4 and prevents the snow, ice and cloudiness from adhering to the lamp lens 4, or the snow, ice and cloudiness adhering to the lamp lens 4 are melted. Is removed or removed. As a result, loss of light irradiated from the front portion 33 of the lamp lens 4 can be prevented.

  At this time, by melting the snow and ice at the portion corresponding to the conductive paste 19 in the front portion 33 of the lamp lens 4, the melted snow and ice slide on the surface of the front portion 33 of the lamp lens 4. Thus, due to a so-called avalanche phenomenon, the snow and ice adhering to the portion not corresponding to the conductive paste 19 in the front portion 33 of the lamp lens 4 are peeled off from the surface of the front portion 33 of the lamp lens 4 and dropped. As a result, snow, ice and cloudiness adhering to the lamp lens 4 can be reliably removed.

  When the heat generation temperature of the line heater 5 reaches a predetermined temperature during the heat generation action of the line heater 5, the current control to the line heater 5 is controlled by the temperature control action of the temperature control unit, and the heat generation temperature of the line heater 5 is reduced. It is kept near a predetermined temperature. As a result, the resin lamp lens 4 having a relatively low heat-resistant temperature can be protected from overheating.

  It is possible to prevent the snow, ice and cloudiness from adhering to the lamp lens 4, and when the snow, ice and cloudiness adhering to the lamp lens 4 are melted or removed, a manual switch and / or an automatic switch can be used. The current supply to the line heater 5 provided in the lens 4 is cut off.

  The line heater transfer jig in the vehicular lamp according to the first embodiment is configured as described above, and the operation and effect thereof will be described below.

  The line heater transfer jig according to the first embodiment uses a receiving jig 27 and a pressure jig 28 to press and transfer the line heater 5 to the front portion 33 of the lamp lens 4. For this reason, the line heater transfer jig according to the first embodiment requires only one pressing direction as compared with the means for transferring the line heater 5 to the lamp lens 4 using a roller or a spatula. The structure of the pressing mechanism is simplified, and the manufacturing cost is reduced accordingly. Moreover, the line heater transfer jig according to the first embodiment can press and transfer almost all the portions of the line heater 5 to the front portion 33 of the lamp lens 4 almost simultaneously by applying pressure in one direction. The transfer can be completed in a short time, and the tact can be shortened. In addition, in the line heater transfer jig according to the first embodiment, the head 30 that presses the line heater 5 against the front portion 33 of the lamp lens 4 is made of a flexible material. By the elastic deformation, the line heater 5 can be reliably transferred to the front portion 33 of the lamp lens 4 (that is, transferred in close contact).

  Further, the line heater transfer jig according to the first embodiment positions and temporarily fixes the separator 21 to the head 30 by fitting the pin 36 as a holding portion provided in the head 30 and the through hole 42 of the separator 21. can do. For this reason, the line heater transfer jig according to the first embodiment can easily set the line heater 5 to the head 30 of the pressure jig 28 via the separator 21 and the separator 21. Moreover, in the line heater transfer jig according to the first embodiment, the line heater 5 can be positioned and set on the head 30 of the pressure jig 28 via the separator 21 and the separator 21. The line heater 5 can be accurately transferred to a predetermined position of the portion 33.

  Further, the line heater transfer jig according to the first embodiment places the portion of the line heater 5 that is not desired to be transferred to the lamp lens 4, that is, the power feeding unit 6 in the groove 43 of the head 30, thereby providing the line heater 5 with the line heater 5. Since it is possible to arbitrarily set a portion that is not desired to be transferred to the lamp lens 4, high-quality transfer can be performed depending on the degree of freedom in setting the transfer portion (heater portion) and non-transfer portion (power feeding portion 6) of the line heater 5. can get. For example, when the power supply unit 6 having a width W1 larger than the width W of the line heater 5 is provided in the line heater 5 and transfer of the power supply unit 6 is difficult compared to transfer of the line heater 5 (if the bonding area is large, In the bonding surface, bubbles, bulges, wrinkles and deflections are likely to occur, and high quality transfer is difficult). By positioning the power supply unit 6 in the groove 43 of the head 30, the power supply unit 6 is transferred to the lamp lens 4. Therefore, it is possible to transfer the line heater 5 to the lamp lens 4, so that a high quality transfer of the line heater 5 can be obtained.

  Furthermore, in the line heater transfer jig according to the first embodiment, the front portion 33 of the lamp lens 4 in which the line heater 5 held on the pressure surface of the head 30 having a small curvature radius R1 via the separator 21 has a large curvature radius R2. When the transfer is performed on the transfer surface, the pressure is sequentially transferred from the apex of the line heater 5 toward the periphery thereof, so that the line heater 5 is less likely to bend and wrinkle, and the line heater 5 is transferred with higher quality. Is obtained.

  FIG. 14 shows Example 2 of the line heater transfer jig in the vehicular lamp according to the present invention. In the figure, the same reference numerals as those in FIGS. 1 to 13 denote the same components. Hereinafter, the line heater transfer jig in the vehicular lamp according to the second embodiment will be described.

  In the line heater transfer jig according to the second embodiment, the pressure surface of the head 300 of the pressure jig 280 is substantially flat. Since the line heater transfer jig according to the second embodiment is configured as described above, it is possible to achieve substantially the same operational effects as those of the line heater transfer jig according to the first embodiment.

  In particular, in the line heater transfer jig according to the second embodiment, since the pressure surface of the head 300 of the pressure jig 280 is substantially flat, the pressure surface of the head 30 of the pressure jig 28 forms a convex curved surface. Compared with the line heater transfer jig according to the first embodiment, the manufacturing is simple, and the manufacturing cost can be reduced accordingly.

1 shows a first embodiment of a line heater transfer jig in a vehicle lamp according to the present invention, wherein the line heater is transferred by the line heater transfer jig, and the vehicle lamp including the lamp lens is a head of an automobile. It is explanatory drawing of the state currently used for the lamp | ramp. Similarly, it is a vertical sectional view (longitudinal sectional view) of the headlamp. Similarly, it is a vertical sectional view (longitudinal sectional view) of a lamp unit used in a headlamp. It is a perspective view which similarly shows the lamp lens currently used for the headlamp. Similarly, it is an enlarged view of the V section in FIG. Similarly, it is the VI-VI sectional view taken on the line in FIG. Similarly, it is a horizontal sectional view (transverse sectional view) showing a wiring state between a part of the headlamps, in particular, the power supply unit and the power supply side. Similarly, it is a top view which shows a wire heater and an electric power feeding part. Similarly, it is explanatory drawing which shows the state which hold | maintains a wire heater on the head of a pressure jig through a separator. Similarly, it is explanatory drawing which shows the state which hold | maintains a lamp lens to a receiving jig, and transfers a line heater to the lamp lens with a pressure jig. Similarly, it is explanatory drawing which shows the manufacturing process of the line heater transferred to a lamp lens, and the transfer process of transferring a line heater to a lamp lens. Similarly, it is explanatory drawing which shows the state which pressure-transfers a line heater with a pressure jig to the lamp lens currently hold | maintained at the receiving jig. Similarly, it is a horizontal sectional view (transverse sectional view) showing a modification of the wiring state of a part of the headlamp, in particular, the power supply unit and the power supply side. Example 2 of the line heater transfer jig in the vehicular lamp according to the present invention is shown, and is an explanatory diagram of a state in which the line heater is pressure-transferred to the lamp lens held by the receiving jig with the pressure jig.

Explanation of symbols

C Automobile CL Cut location W Base film width W1 Film width R1 Curvature radius of the pressure surface of the head R2 Curvature radius of the transfer surface of the lamp lens 1L, 1R Headlamp (vehicle lamp)
DESCRIPTION OF SYMBOLS 2 Lamp unit 3 Lamp housing 4 Lamp lens 5 Wire heater 6 Feeding part 7 Lamp chamber 8 Upper reflector 9 Lower reflector 10 Reflecting surface 11 Shade 12 Semiconductor type light source (LED)
13 Projection lens 14 Heat sink member 15 Holder member 16 Heat sink member 17 Base film 18 Adhesive 19 Conductive paste (conductive member for heater)
20 Resist 21 Separator 22 Release Sheet 23 Sheet Member 24 Film 25 Conductive Paste (Power Supply Conductive Member)
26 Connector 27 Receiving jig 28, 280 Pressure jig 29 Recessed part 30, 300 Head 31 Connecting member 32 Adhesive 33 Front part 34 Side wall part 35 Heater side harness 36 Pin (holding part)
37 Heater side connector 38 Waterproof grommet 39 Power source side harness 40 Power source side connector 41 Vehicle parts 42 Through hole 43 Groove 49 Wide part

Claims (4)

In a vehicular lamp where the lamp lens has a snow melting structure,
A jig for transferring a line heater to the lamp lens,
A jig for receiving the lamp lens;
A pressure jig that holds the line heater via a separator and pressurizes and transfers the line heater to the lamp lens received by the jig;
With
The pressure jig is provided with a head that holds the wire heater via the separator and pressurizes the lamp lens, and the head is made of a flexible material.
A wire heater transfer jig in a vehicular lamp characterized by the above.   The line heater transfer jig in the vehicular lamp according to claim 1, wherein the head is provided with a holding portion that positions and temporarily fixes the separator.   The line heater has a portion that is not transferred to the lamp lens, and a groove corresponding to the portion of the head is provided with a groove that avoids the portion. 3. A line heater transfer jig in the vehicular lamp according to 2.   The surface of the lamp lens on which the line heater is transferred and the pressure surface of the head are curved surfaces, and the radius of curvature of the pressure surface of the head is smaller than the radius of curvature of the transfer surface of the lamp lens. The line heater transfer jig in the vehicular lamp according to any one of claims 1 to 3.

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