JP2013175320A - Method of manufacturing vehicle lamp - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a vehicle lamp, configured to prevent a parting line from being generated on a design surface of a reflector or an extension, and to reduce the size of a nest for easy replacement.SOLUTION: A vehicle lamp is provided with a reflector 10, 10' which includes a reflection face 10a, 10a' for reflecting light from a light source bulb 9, 9', and has a bulb fitting hole 12, 12' formed for fitting the light source bulb 9, 9'. In a method of manufacturing the reflector 10, 10' by injection molding of resin, at least one of a fixed die or a movable die for forming a cavity corresponding to a shape of the reflector 10, 10' is provided removably with a nest 20, 20'. An installation range of the nest 20, 20' is set at a bulb fitting hole 12 of the reflector 10 and a part 10a1 of its surrounding reflection face 10a or a bulb fitting hole 12' of the reflector 10'.

Description

  The present invention relates to a manufacturing method by injection molding of a reflector or extension of a vehicular lamp.

  For example, a vehicular lamp such as a position lamp or a DRL lamp is provided with a light source bulb and a reflector that reflects light from the light source bulb, and the reflector is manufactured by injection molding with a resin (for example, , See Patent Document 1).

  By the way, even if the appearance of the position lamp and the DRL lamp is the same, the light distribution performance differs depending on each function. Therefore, the reflectors have different shapes in order to satisfy the light distribution performance required for each lamp. It was necessary to prepare a plurality of types having a reflecting surface.

  However, manufacturing different types of reflectors as described above has a problem that the mold cost increases and the manufacturing cost increases.

  Therefore, in Patent Document 2, a part of the reflecting surface (portion near the optical axis) of the lamp body (housing) is molded using a nest that is detachably attached to the mold, and only the nest is used as a lamp type. A configuration for replacement according to the proposal has been proposed. Here, a manufacturing method of the reflector using the insert is shown in FIGS.

  3A is a side sectional view showing a manufacturing method using a reflector insert of a position lamp, and FIG. 3B is a side sectional view showing a manufacturing method using a reflector insert of a DRL lamp. In the manufacture by injection molding of the reflector 110 of the position lamp 106 shown in FIG. 3A, the reflecting surface 110a of the reflector 110 is formed using the inserts 120 and 121. In addition, in the manufacture by injection molding of the reflector 110 ′ of the DRL lamp 106 ′ shown in FIG. 3B, the reflecting surface 110 a ′ of the reflector 110 ′ is formed using the inserts 120 ′ and 121 ′.

  Here, the shapes of the reflecting surfaces 110a and 110a ′ of the reflector 110 of the position lamp 106 shown in FIG. 3A and the reflector 110 ′ of the DRL lamp 106 ′ shown in FIG. 3B satisfy the desired light distribution performance. Therefore, the shape of the nest 120 shown in FIG. 3A and the shape of the nest 120 ′ shown in FIG. 3B are also different from each other.

Japanese Patent Laid-Open No. 10-175232 JP 2002-313107 A

  However, in the conventional manufacturing method shown in FIGS. 3 (a) and 3 (b), the installation range of the nestings 120 and 120 ′ is on the outer periphery of the reflecting surfaces 110a and 110a ′, which are the design surfaces of the reflectors 110 and 110 ′. Therefore, a parting line (border line of the mold matching portion) is generated on the design surface that is easily noticeable of each reflector 110, 110a, and the inner peripheral corner portion (illustrated) of the design surface of each reflector 110, 110a ′. There is a problem that a sharp pin angle is formed in the part a).

  In addition, since the installation range of each nesting 120, 120 'is wide, there is a problem that replacement of the nesting 120, 120' becomes large and replacement is difficult.

  The present invention has been made in view of the above problems, and the object of the present invention is that no parting line is generated on the design surface of the reflector or the extension, and the size of the nesting is reduced and this can be easily replaced. The object is to provide a method for manufacturing a vehicular lamp.

  In order to achieve the above object, the invention according to claim 1 is for a vehicle including a reflector or extension having a reflecting surface for reflecting light from the light source bulb and having a bulb mounting hole for mounting the light source bulb. A method of manufacturing the reflector or extension of a lamp by injection molding of a resin, wherein a nest is detachably attached to at least one of a fixed mold and a movable mold that form a cavity corresponding to the shape of the reflector or extension. The installation range of the insert is set to the valve mounting hole of the reflector or the extension and a part of the reflection surface around it or the valve mounting hole.

  According to a second aspect of the present invention, in the first aspect of the present invention, a portion corresponding to a part of the reflecting surface of the reflector or extension included in the installation range of the insert is shaped to match each specification of the vehicular lamp. The other part of the reflecting surface is formed in a shape common to vehicle lamps having different specifications.

  According to a third aspect of the present invention, in the first aspect of the present invention, the installation range of the nest set in the bulb mounting hole of the reflector or extension is the largest of the bulb mounting holes of the vehicular lamp having different specifications. It is characterized by adapting to things.

  According to the first aspect of the present invention, the installation range of the insert detachably attached to at least one of the fixed mold and the movable mold is set to the reflector or extension valve mounting hole and a part of the reflection surface around it or the valve. Since the mounting hole is set, the size of the insert is reduced, and a parting line is not generated on the design surface where the reflector or extension is conspicuous, thereby improving the appearance quality of the vehicular lamp. In addition, by reducing the size of the nest, the nest becomes lighter and can be easily replaced to increase productivity.

  According to the second aspect of the present invention, the nest is exchanged according to each vehicle lamp having different specifications, and a part of the reflecting surface of the reflector or extension of the vehicle lamp is formed by nest, thereby The light distribution performance required for the lamp can be satisfied. And since the other part (part which is not formed by nesting) of a reflective surface was made into the shape common to the vehicle lamp with a different specification, metal molds other than nesting can be used in common with respect to all the vehicle lamps. The mold cost can be kept low and the manufacturing cost can be reduced.

  According to the invention of claim 3, by setting the installation range of the nest set in the bulb mounting hole of the reflector or extension to the largest one of the bulb mounting holes of the reflector of the vehicle lamp having different specifications, The nesting size can be minimized.

It is a front view of a vehicle lamp. FIG. 2 is a cross-sectional view taken along line AA in FIG. 1, where (a) is a side cross-sectional view of a position lamp showing a manufacturing method of a reflector according to the present invention, and (b) is a DRL lamp side showing a manufacturing method according to the present invention. It is sectional drawing. (A) is a side sectional view of a position lamp showing a manufacturing method of a conventional reflector, (b) is a side sectional view of a DRL lamp showing a manufacturing method of a conventional reflector.

  Embodiments of the present invention will be described below with reference to the accompanying drawings.

  1 is a front view of a vehicular lamp, FIG. 2 is a cross-sectional view taken along line AA of FIG. 1, and (a) is a side cross-sectional view of a position lamp showing a method of manufacturing a reflector according to the present invention. These are sectional side views of a DRL lamp showing the manufacturing method according to the present invention.

  A vehicle lamp 1 shown in FIG. 1 is a front combination lamp disposed on the left and right of the front part of a vehicle. The front combination lamp 1 is a transparent cover that covers a housing 2 and its front opening as shown in FIG. A head lamp 5 and a position lamp 6 shown in FIG. 2A or a DRL lamp 6 ′ shown in FIG. 2B are accommodated in a lamp chamber 4 defined by the outer lens 3.

  The headlamp 5 includes a light source bulb 7 and a reflector 8 that reflects light from the light source bulb 7 toward the front of the vehicle (front side in FIG. 1). The position lamp 6 shown in FIG. 2 (a) and the DRL lamp 6 'shown in FIG. 2 (b) are arranged beside the headlamp 5, and the appearance and size of both are exactly the same. Is set. The position lamp 6 shown in FIG. 2A includes a light source bulb 9 and a reflector 10, and the DRL lamp 6 ′ shown in FIG. 2B also includes a light source bulb 9 ′ and a reflector 10 ′. Yes. Here, in the position lamp 6 shown in FIG. 2 (a), a bulb mounting hole 11 and a bulb mounting hole 12 are formed at the center of the housing 2 and the reflector 10, respectively. The socket 13 is inserted into the lamp chamber 4 from the formed bulb mounting hole 11 and is fixed to the housing 2 by mounting the socket 13 mounted in the bulb mounting hole 11 of the housing 2. It passes through the attachment hole 12 and faces the inside of the reflector 10. Similarly, in the DRL lamp 6 ′ shown in FIG. 2 (b), a bulb mounting hole 11 ′ and a bulb mounting hole 12 ′ are formed in the center of the housing 2 and the reflector 10 ′, respectively, and the light source bulb 9 ′. Is inserted into the lamp chamber 4 from a bulb mounting hole 11 ′ formed in the housing 2, and fixed to the housing 2 by mounting a socket 13 ′ mounted on the bulb mounting hole 11 ′ in the housing 2, The light emitting portion passes through the bulb mounting hole 12 ′ of the reflector 10 ′ and faces the inside of the reflector 10 ′.

  By the way, the position lamp 6 shown in FIG. 2A and the DRL lamp & ′ shown in FIG. 2B have different light distribution performances due to the difference in function, and the light source bulb 9 of the position lamp 6 has a DRL lamp. A smaller one than the light source bulb 9 'of 6' is used. Further, the reflecting surface 10a on the inner surface of the reflector 10 of the position lamp 6 and the reflecting surface 10a 'of the reflector 10 of the DRL lamp 6' are arranged so as to satisfy the light distribution performance required for the position lamp 6 and the DRL lamp 6 '. Each shape is set.

  Thus, the reflector 10 of the position lamp 6 and the reflector 10 'of the DRL lamp 6' are both integrally formed by resin injection molding. That is, a cavity corresponding to the shape of the reflector 10, 10 'is formed by a fixed mold and a movable mold (not shown), molten resin is poured into the cavity and filled, and the filled molten resin is cooled and solidified. By doing so, the reflectors 10 and 10 'are respectively manufactured.

  By the way, a nest has been conventionally used for manufacturing a reflector for a position lamp and a reflector for a DRL lamp. That is, it has been conventionally performed to manufacture reflectors having different specifications by attaching a detachable insert to at least one of a fixed mold and a movable mold and exchanging the insert. The method is characterized in that the installation range of the nesting is set to the valve mounting hole of the reflector and a part of the reflection surface around it or the valve mounting hole.

  Specifically, in the manufacture of the reflector 10 of the position lamp 6 shown in FIG. 2A, two inserts 20 and 21 are used, and the installation range of one insert 20 is set to the bulb mounting hole 12 of the reflector 10 and its A part 10a1 of the surrounding reflecting surface 10a is used. Here, of the reflecting surface 10a of the reflector 10, a part of the reflecting surface 10a1 (portion around the bulb mounting hole 12) formed by the insert 20 satisfies the light distribution characteristic required for the position lamp 6. The other portion 10a2 of the reflecting surface 10a is set to a shape that can satisfy both the light distribution performance required for the position lamp 6 and the DRL lamp 6 ′.

  Also, in the manufacture of the reflector 10 ′ of the DRL lamp 6 ′ shown in FIG. 2B, two inserts 20 ′ and 21 ′ are used, but the installation range of one insert 20 ′ is the bulb of the reflector 10 ′. The mounting hole 12 'is set. That is, the range of the nesting 20 ′ is the largest of the bulb mounting holes 12 and 12 ′ of the two reflectors 10 and 10 ′ having different specifications, that is, the reflector 10 ′ of the DRL lamp 6 ′ shown in FIG. The size is matched to the size of the valve mounting hole 12 'formed in the above.

  As described above, according to the manufacturing method according to the present embodiment, in the manufacture of the reflector 10 of the position lamp 6 shown in FIG. 2A, the installation range of the insert 20 is set to the bulb mounting hole 12 of the reflector 10 and its In the manufacture of the reflector 10 ′ of the DRL lamp 6 ′ shown in FIG. 2 (b) with the part 10a1 of the surrounding reflecting surface 10a, the installation range of the insert 20 ′ is set in the bulb mounting hole 12 ′ of the reflector 10 ′. The sizes of the inserts 20 and 20 ′ are reduced, and a parting line is not generated on the design surface where the reflectors 10 and 10 ′ are easily noticeable, so that the appearance quality of the position lamp 6 and the DRL lamp 6 ′ is improved. Further, since the size of the inserts 20 and 20 ′ is reduced, the inserts 20 and 20 ′ can be reduced in weight and can be easily replaced to increase productivity. In particular, in the present embodiment, since the size of both nestings 20 and 20 ′ can be set to the size of the bulb mounting hole 12 ′ of the reflector 10 ′ of the DRL lamp 6 ′, the size of both nestings 20 and 20 ′. Can be minimized.

  Further, in the present embodiment, in manufacturing the reflector 10 of the position lamp 6, since the part 10a1 of the reflecting surface 10a of the reflector 10 is formed by the insert 20, the light distribution performance required for the position lamp 6 is achieved. Can be satisfied. Since the other part 10a2 of the reflecting surface 10a of the reflector 10 (the part not formed by the nesting 20) has a shape common to the reflecting surface 10a 'of the reflector 10' of the DRL lamp 6 having different specifications, other than the nestings 20 and 20 '. Can be used in common in the manufacture of the reflector 10 of the position lamp 6 and the reflector 10 ′ of the DRL lamp 6 ′, so that the mold cost can be kept low and the manufacturing cost can be reduced.

  In the above embodiment, the method for manufacturing the reflector for the position lamp and the DRL lamp has been described. However, the present invention is also applicable to the manufacture of a reflector or extension for a vehicle lamp other than the position lamp and the DRL lamp. Of course, the same applies.

1 Front combination lamp (vehicle lamp)
2 Housing 3 Outer lens 4 Lamp chamber 5 Head lamp 6 Position lamp 6 'DRL lamp 7 Light source bulb 8 Reflector 9, 9' Light source bulb 10, 10 'Reflector 10a Reflective surface 10a1 Part of reflective surface 10a2 Other part of reflective surface 10a 'Reflection surface 11, 11' Valve mounting hole 12, 12 'Valve mounting hole 13, 13' Socket 20, 20 'Nest 21,21' Nest

Claims (3)

A method of manufacturing the reflector or extension of a vehicular lamp having a reflecting surface that reflects light from the light source bulb and having a bulb attachment hole for attaching the light source bulb by injection molding of resin Because
The insert is detachably attached to at least one of a fixed mold and a movable mold that form a cavity corresponding to the shape of the reflector or extension, and the installation range of the insert is set to the valve mounting hole of the reflector or extension and the surrounding area. A method for manufacturing a vehicular lamp, wherein the vehicular lamp is set in a part of a reflecting surface or a bulb mounting hole.   The part corresponding to a part of the reflecting surface of the reflector or the extension included in the installation range of the nesting is shaped to match each specification of the vehicle lamp, and the other part of the reflecting surface is common to the vehicle lamp having different specifications The method for manufacturing a vehicular lamp according to claim 1, wherein the vehicle lamp has a shape of 2. The vehicular lamp according to claim 1, wherein an installation range of the nest set in the bulb mounting hole of the reflector or the extension is matched with a maximum one of the bulb mounting holes of the vehicular lamp having different specifications. Manufacturing method.

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