JP2011056667A - Method of manufacturing plastic lighting cover - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a plastic lighting cover, which has high strength and can surely diffuse light from a light source, through a simple process. <P>SOLUTION: In the method of manufacturing a plastic lighting cover: a thermoplastic resin material is extruded into a substantially flat plate by an extruder; a body 11 with a substantially linear cross section and a substrate A of a cover member 1 having latching projections 12 and 12 in both ends of the width direction of the body 11 respectively are produced; a rugged groove 13 is formed on the surface of the body 11 by embossing a rugged pattern on one surface or each of both surfaces of the body 11 of the substrate A in a heated and softened state; and while the substrate A is in the heated and softened state, the substrate A is inserted into an inlet die 21 of a molding die 2 having a substantially linear cross section. Inside the cavity of the molding die 2, the inserted body 11 is curved and molded along the wall surface shape wherein a region between both wall faces gradually changes from a linear shape to a curved shape, and then ejected from a curved outlet die 22. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to an improvement of a lighting fixture using a light emitting diode or the like as a light source, and more specifically, a method for manufacturing a plastic lighting cover capable of reliably diffusing light from a light source with high strength through a simple process. It is about.

  As is well known, recent light-emitting diodes have high brightness and are therefore actively used as a light source for illumination. At this time, the light-emitting diodes are covered with a cover to diffuse direct light and adjust the amount of light.

  Conventionally, as a cover member capable of adjusting the amount of light in this manner, a cover member formed by kneading a light diffusing agent into a plastic material of the cover material has been disclosed (for example, see Patent Document 1).

  However, there is a problem that the cost of the light diffusing agent material itself is increased, and manufacturing accuracy is also required so as not to cause unevenness in kneading. .

  Further, there is disclosed a method in which light from a light source is scattered by the uneven portions by forming uneven grooves on the surface of the cover member by an extrusion molding method (see, for example, Patent Document 2).

  However, since the plastic material extrusion molding method determines the cross-sectional shape of the molded product depending on the shape of the die, when forming the concave and convex grooves on the surface of the cover material, only the one extending in the longitudinal direction of the main body, which is the extrusion direction, is used. There is a problem that the concave and convex grooves extending in the longitudinal direction cannot be molded and are easily broken along the concave and convex grooves.

JP 2006-237114 A Registered Utility Model No. 3102083

  The present invention has been made in view of the above-described problems with illumination covers used in conventional light-emitting diodes, and the object thereof is a simple process, high strength, and from a light source. Another object of the present invention is to provide a method of manufacturing a plastic lighting cover that can reliably diffuse light.

  Means employed by the present inventor for solving the above technical problem will be described with reference to the accompanying drawings.

That is, in the present invention, the thermoplastic resin material is extruded into a substantially flat plate shape by an extruder, and the main body part 11 having a substantially straight cross-sectional shape and the latching convex parts at both ends in the width direction of the main body part 11 are respectively provided. While producing the substrate A of the cover member 1 having 12 · 12,
A concave / convex pattern is embossed on one or both sides of the main body 11 of the substrate A in the heat softened state to form a concave / convex groove 13 on the surface of the main body 11,
While the substrate A is in the heat softened state, the substrate A is inserted into the inlet die 21 of the shaping mold 2 having a substantially linear cross-sectional shape,
In the cavity of the shaping mold 2, the inserted body portion 11 is bent and shaped along the wall shape in which the region sandwiched between both wall surfaces gradually changes from a straight shape to a curved shape, By extruding from the curved exit die 22,
By adopting technical means to form a light diffusing surface that can diffuse the light irradiation from the light source inside the curved surface by the concave and convex grooves 13 continuous along the circumferential direction of at least the inner surface of the curved housing, it is made of plastic. The manufacturing method of the lighting cover was completed.

In the present invention, the thermoplastic resin material is extruded into a curved shape having a predetermined curvature by an extrusion molding machine, and the main body portion 11 having a curved cross-sectional shape and the latching convex portions 12 are provided at both end portions in the width direction of the main body portion 11, respectively. While producing the substrate A of the cover member 1 having 12
The substrate A in a heat-softened state is urged and developed in a substantially flat plate shape, and an uneven pattern is embossed on one or both surfaces of the main body 11 to form an uneven groove 13 on the surface of the main body 11. And
While the substrate A is in the heat softened state, the substrate A is inserted into the entrance die 21 of the shaping mold 2 having a curved cross-sectional shape with a predetermined curvature,
In the cavity of the shaping mold 2, the main body portion 11 is inserted along a curved cross-section wall surface having a predetermined curvature or a wall surface shape that gradually increases in curvature. By bending it and pushing it out of the curved outlet die 22
The technical means of forming a light diffusion surface capable of diffusing light irradiation from the light source on the inner side of the curved surface can be adopted by the concave and convex grooves 13 continuous along the circumferential direction of at least the inner side surface of the curved housing.

  Further, in order to solve the above problems, the present invention, in addition to the above means, in addition to the above means, on the surface of the main body portion 11 of the cover member 1, linear concave and convex grooves 13, 13. Technical means of forming can be employed.

  Furthermore, in order to solve the above-mentioned problems, the present invention adds the concave / convex pattern to the main body portion 11 by a press press machine P which moves the cover member 1 intermittently and moves up and down in the vertical direction in addition to the above means as necessary. It is possible to adopt a technical means for continuously forming the concave / convex grooves 13 by embossing the surface.

  Furthermore, in order to solve the above-mentioned problems, the present invention, in addition to the above-described means as necessary, continuously transports the cover member 1 and attaches a rolling roll R having a concavo-convex pattern on the surface of the main body 11. It is possible to employ a technical means of continuously forming the concave and convex grooves 13 by embossing the surface.

  Furthermore, in order to solve the above-mentioned problems, the present invention employs technical means for making the bent shape of the exit die 22 of the shaping die 2 into a substantially semicircular arc shape in addition to the above means as necessary. can do.

  In the present invention, the thermoplastic resin material is extruded into a substantially flat plate shape by an extrusion molding machine, and is hung on each of the main body portion having a substantially linear shape or a cross section of a small curvature curve and both end portions in the width direction of the main body portion. While producing the cover member substrate with the convex part, the concave / convex pattern is embossed on one or both sides of the main body part of the heat-softened substrate to form the concave / convex groove on the surface of the main body part At the same time, while the substrate is in the heat softening state, the substrate is inserted into the entrance die of the shaping mold, and the region sandwiched between both wall surfaces is gradually increased in the cavity of the shaping die. Continuously along the circumferential direction of at least the inner surface of the curved housing by bending the inserted main body portion along the wall shape that changes into a curved shape and pushing it out from the curved exit die By the uneven groove to The light irradiation from the light source in curved inner can form a diffusible light diffusing surface.

  Therefore, by using the plastic lighting cover manufacturing method of the present invention, it is possible to reliably diffuse the light from the light source with a high strength in a simple process. It can be said that the utility value of is great.

It is a perspective view showing the manufacturing process of the cover member of 1st Embodiment of this invention. It is sectional drawing showing the manufacturing process of the cover member of 1st Embodiment of this invention. It is sectional drawing showing the manufacturing process of the cover member of 1st Embodiment of this invention. It is sectional drawing showing the manufacturing process of the cover member of 1st Embodiment of this invention. It is sectional drawing showing the manufacturing process of the cover member of 1st Embodiment of this invention. It is a perspective view showing the intermediate product of the cover member of 1st Embodiment of this invention. It is a perspective view showing the structure of the shaping die of 1st Embodiment of this invention. It is a perspective view showing the structure of the shaping die of 1st Embodiment of this invention. It is a perspective view showing the cover member of 1st Embodiment of this invention. It is a perspective view showing the use condition of the cover member of 1st Embodiment of this invention. It is a perspective view showing the manufacturing process of the cover member of 2nd Embodiment of this invention. It is a perspective view showing the structure of the shaping die of 2nd Embodiment of this invention. It is a perspective view showing the intermediate product of the modification of the cover member of embodiment of this invention. It is a perspective view showing the modification of the cover member of embodiment of this invention.

  The embodiment for carrying out the present invention will be described in more detail with reference to the drawings specifically illustrated as follows.

“First Embodiment”
A first embodiment of the present invention will be described with reference to FIGS. In the figure, what is indicated by reference numeral 1 is a cover member, and what is indicated by reference numeral 2 is a shaping die.

  Therefore, a method for manufacturing the plastic lighting cover in this embodiment will be described below. First, a thermoplastic resin material is extruded into a substantially flat plate shape by an extrusion molding machine M, and latching convex portions 12 and 12 are respectively provided at the main body portion 11 having a substantially straight cross-sectional shape and both end portions in the width direction of the main body portion 11. The substrate A of the cover member 1 having the above is manufactured (see FIG. 1).

  In the present embodiment, polycarbonate (PC) or polymethyl methacrylate resin (acrylic) (PMMA) is employed as the thermoplastic resin that is the material of the cover member 1 in terms of strength, moldability, and transparency.

  Next, the concave / convex pattern is embossed on one surface (or both surfaces) of the main body portion 11 of the substrate A in the heat softened state to form the concave / convex grooves 13 on the surface of the main body portion 11. In the present embodiment, for example, as shown in FIGS. 2 to 4, while the cover member 1 is intermittently moved (stop, go, stop, etc.) and sent out, the press press machine P moves up and down in the vertical direction. The concave / convex grooves 13 can be continuously formed by embossing the concave / convex pattern on the surface of the main body 11. The concavo-convex groove 13 can be transferred with a concavo-convex shape, a wave shape, an acute-angle shape, etc., with a pitch (interval) of 0.01 to 3 mm and a depth of 0.01 to 1 mm. Note that the feeding of the cover member 1 is not limited to intermittent movement but can be continuously carried out at a constant speed. At this time, the pressing machine P can be embossed while moving in synchronization with the feeding speed. .

  Further, in the present embodiment, on the surface of the main body portion 11 of the cover member 1, linear uneven grooves 13, 13,... Extending in the width direction can be formed in parallel.

  As shown in FIG. 5, the cover member 1 is continuously transferred, and the rolling roll R having a concavo-convex pattern on the surface is embossed on the surface of the main body portion 11 to continuously form the concavo-convex grooves 13. It can also be formed.

  Next, while this substrate A, which is an intermediate product as shown in FIG. 6, is in the heat-softening state of the substrate A, the inlet die 21 of the shaping mold 2 (in this embodiment, a substantially straight cross section) Shape). That is, the shape of the inlet die 21 is slightly larger than the cross-sectional shape having the main body part 11 having a substantially straight cross-sectional shape and the latching convex parts 12 and 12 at both ends in the width direction of the main body part 11, respectively. Have been made.

  Then, in the cavity of the shaping mold 2, the inserted body portion 11 is bent and shaped along the wall surface shape in which the region sandwiched between both wall surfaces gradually changes from a linear shape to a curved shape. Then, it is extruded from the exit die 22 having a curved shape (in this embodiment, a substantially semicircular arc shape) (see FIGS. 7 and 8). At this time, it is preferable to prevent the mold wall surface from rubbing the molding surface of the concavo-convex groove 13 during the passage shaping of the main body 11 in the cavity.

  Then, the cover member 1 extruded from the outlet die 22 is cooled by the sizing die of the shaping die 2 or cured by natural cooling or positive cooling after being discharged, and is made of the plastic of the present invention. The lighting cover is completed (see FIG. 9).

  By manufacturing by the above method, it is possible to form a light diffusion surface capable of diffusing light irradiation from the light source on the inside of the curved surface by the concave and convex grooves 13 continuous along the circumferential direction of at least the inner side surface of the curved housing. .

  Then, as shown in FIG. 10, the cover member 1 of the present invention is sandwiched and combined with an aluminum casing C to which a light source L such as a light emitting diode is fixed, and engaging projections 12 and 12, for illumination. An instrument can be configured.

“Second Embodiment”
A second embodiment of the present invention will be described with reference to FIGS. In the present embodiment, the thermoplastic resin material is extruded into a curved shape having a predetermined curvature by the extrusion machine M, and the latching convex portions 12 are respectively provided at the curved cross-sectional shape of the main body portion 11 and both ends of the main body portion 11 in the width direction. -The board | substrate A of the cover member 1 which has 12 is produced (refer FIG. 11).

  Next, the heat-softened substrate A is urged and developed in a substantially flat plate shape. About this urging | deployment expansion | deployment, a load is applied with the stress within the range of elastic deformation so that it may not reach plastic deformation. Then, in the substantially flat plate state, the concave / convex pattern is embossed on one surface (or both surfaces) of the main body portion 11 to form the concave / convex grooves 13 on the surface of the main body portion 11 as in the first embodiment. Form.

  By adopting such a manufacturing method, it is possible to improve the strength by aligning the molecular orientation of the resin on the surface of the main body portion 11 in the circumferential direction, and to stabilize the form of the uneven groove 13.

  Next, as shown in FIG. 12, while the substrate A is in the heat softened state, the substrate A is inserted into the entrance die 21 of the shaping die 2 (in the present embodiment, the curved cross-sectional shape having the predetermined curvature). That is, the shape of the inlet die 21 is a cross-sectional shape having a curved cross-sectional main body 11 extruded from the extruder M and latching convex portions 12 and 12 at both ends in the width direction of the main body 11. It is made in a slightly larger shape.

  In the cavity of the shaping mold 2, the main body inserted along the wall surface shape where the region sandwiched between both wall surfaces changes from a curved shape having a small curvature to a curved shape in which the curvature gradually increases. The part 11 is bent and extruded from the bent outlet die 22. At this time, both the shape of the inlet die 21 and the shape of the outlet die 22 are cavities having a curved cross-sectional wall surface with a predetermined curvature that is a curved cross-sectional shape extruded from the extruder M, You may make it pass shape.

  Similarly to the first embodiment, the cover member 1 pushed out from the outlet die 22 is cooled by the sizing die of the shaping die 2 or cured by natural cooling or positive cooling after discharging. Thus, the plastic lighting cover of the present invention is completed.

  The present invention is generally configured as described above. However, the present invention is not limited to the illustrated embodiment, and various modifications can be made within the scope of the claims, for example, a cover member. The shape of one uneven groove 13 may be an uneven pattern intersecting each other as shown in FIGS.

  In addition, a known light diffusing agent can be kneaded into the resin material of the cover member 1 to be translucently molded. Examples of the light diffusing agent include titanium oxide, aluminum oxide, silicon oxide, quartz, and barium titanate. Can be used.

  Furthermore, the cross-sectional shape of the cover member 1 is not limited to a substantially semicircular shape, and may be a superior arc shape or an inferior arc shape, or a polygon such as a triangle or a rectangle. It belongs to the technical scope of the invention.

1 Cover member
11 Body
12 Suspension convex
13 Uneven groove A Substrate 2 Mold
21 entrance die
22 Exit die M Extruder P Press press R Rolling roll L Light source C Casing

Claims (6)

A thermoplastic resin material is extruded into a substantially flat plate shape by an extruder, and a cover having a substantially linear cross-sectional main body 11 and latching convex portions 12 and 12 at both ends in the width direction of the main body 11 respectively. While producing the substrate A of the member 1,
A concave / convex pattern is embossed on one or both sides of the main body part 11 of the substrate A in a heat-softened state to form the concave / convex grooves 13 on the surface of the main body part 11;
While the substrate A is in the heat softened state, the substrate A is inserted into the inlet die 21 of the shaping mold 2 having a substantially linear cross-sectional shape,
In the cavity of the shaping mold 2, the inserted body portion 11 is bent and shaped along the wall shape in which the region sandwiched between both wall surfaces gradually changes from a straight shape to a curved shape, By extruding from the curved exit die 22,
A method for producing a plastic lighting cover, characterized in that a light diffusion surface capable of diffusing light irradiation from a light source on the inner side of a curved surface is formed by the concave and convex grooves 13 continuous along the circumferential direction of at least the inner side surface of the curved housing. . A thermoplastic resin material is extruded into a curved shape having a predetermined curvature by an extrusion molding machine, and a cover member having a curved cross-sectional shape of the main body portion 11 and latching convex portions 12 and 12 at both ends in the width direction of the main body portion 11, respectively. While producing one substrate A,
The substrate A in a heat-softened state is urged and developed in a substantially flat plate shape, and an uneven pattern is embossed on one or both surfaces of the main body 11 to form an uneven groove 13 on the surface of the main body 11. And
While the substrate A is in the heat softened state, the substrate A is inserted into the entrance die 21 of the shaping mold 2 having a curved cross-sectional shape with a predetermined curvature,
In the cavity of the shaping mold 2, the main body portion inserted along the curved wall surface where the region sandwiched between both wall surfaces changes to a curved sectional wall surface with a predetermined curvature or a curved shape with gradually increasing curvature. By curving the 11 and pushing it out of the curved exit die 22,
A method for producing a plastic lighting cover, characterized in that a light diffusion surface capable of diffusing light irradiation from a light source on the inner side of a curved surface is formed by the concave and convex grooves 13 continuous along the circumferential direction of at least the inner side surface of the curved housing. .   3. The method for manufacturing a plastic lighting cover according to claim 1, wherein linear uneven grooves 13, 13... Extending in the width direction are formed in parallel on the surface of the main body 11 of the cover member 1.   The concave / convex groove 13 is continuously formed by embossing the concave / convex pattern on the surface of the main body 11 by a press press P that moves the cover member 1 intermittently and moves up and down in the vertical direction. Item 4. A method for producing a plastic lighting cover according to any one of Items 1 to 3.   The cover member 1 is continuously transferred, and a rolling roller R having a concavo-convex pattern on the surface thereof is embossed on the surface of the main body portion 11 to continuously form the concavo-convex groove 13. The manufacturing method of the plastic lighting cover as described in any one of 1-3.   6. The method of manufacturing a plastic lighting cover according to claim 1, wherein the bent shape of the exit die 22 of the shaping mold 2 is a substantially semicircular arc.