JP4021120B2 - Vehicle lamp manufacturing equipment - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a vehicle lamp manufacturing apparatus for welding a front lens and a lamp body by so-called hot plate welding.
[0002]
[Prior art]
As a method of joining a front lens and a lamp body of a vehicular lamp, conventionally, indirect joining (for example, hot-melt seal etc.) in which both are joined via a sealing material, and both are brought into direct contact and joined. Direct bonding (for example, hot plate welding, vibration welding, ultrasonic welding, etc.) is known.
[0003]
As shown in FIG. 5, the hot plate welding which is one of the direct bondings described above is performed by heating the planned welding surface 16 b of the front lens 16 and the planned welding surface 14 b of the lamp body 14, and then both the planned welding surfaces 16 b, The front lens 16 and the lamp body 14 are welded together by pressure-contacting 14b.
[0004]
As shown in the figure, the manufacturing apparatus for performing the hot plate welding includes a lens holding jig 102 for holding the front lens 16, a body holding jig 104 for holding the lamp body 4, and the both welding schedules on both sides. A heating element 106 having a lens heating surface 106a and a body heating surface 106b having substantially the same surface shape as the surfaces 16b and 14b is provided. Then, the heating is performed by bringing both welding scheduled surfaces 16b and 14b into contact with the lens heating surface 106a and the body heating surface 106b.
[0005]
[Problems to be solved by the invention]
However, in the above-described conventional manufacturing apparatus, due to variations in the dimensions of the front lens 16 and the lamp body 14 or a dimensional accuracy error of the apparatus itself, both the welding scheduled surfaces 16b and 14b are applied to the lens heating surface 106a and the body heating surface 106b. When contacting, a compression load often acts on the contact surface.
[0006]
When such a compressive load is applied, as shown in FIG. 5A, the portions near the welding planned surfaces 16b and 14b are deformed, and foam burrs p1 and p2 are generated on both sides. When the front lens 16 and the lamp body 14 are welded by pressing the two welding planned surfaces 16b and 14b on which such foam burrs p1 and p2 are generated as shown in FIG. As shown in the figure (c), in the vehicular lamp as a finished product, fairly large foam burrs P are generated on both sides of the welding surface. And since this burr | flash burr | flash P can be seen from the lamp | ramp exterior through the front lens 16, there exists a problem that the appearance of the welding surface periphery will be impaired greatly as a vehicle lamp.
[0007]
Further, in the above-described conventional manufacturing apparatus, the front lens 16 and the planned welding surfaces 16b and 14b of the lamp body 14 come into contact with the lens heating surface 106a and the body heating surface 106b of the heating element 106 during the heating. It is necessary to subject the heating surface 106a and the body heating surface 106b to surface treatment for promoting release. Moreover, this surface treatment needs to be performed periodically. Further, since a synthetic resin material such as AAS or ABS is used as the material of the lamp body 14, a stringing phenomenon tends to occur when the planned welding surface 14b is separated from the body heating surface 106b of the heating element 106. When such a yarn drawing phenomenon occurs, there is also a problem that the yarn drawing portion remains in the lamp chamber of the vehicular lamp after welding, causing a defective appearance.
[0008]
The present invention has been made in view of such circumstances, and in a vehicular lamp manufacturing apparatus for welding a front lens and a lamp body by hot plate welding, the appearance around the welding surface is greatly impaired. It is an object of the present invention to provide an apparatus for manufacturing a vehicular lamp that can be welded efficiently and efficiently.
[0009]
[Means for Solving the Problems]
The present invention is intended to achieve the above object by devising the arrangement of the front lens and lamp body and the structure of the heating element during welding.
[0010]
That is, the vehicle lamp manufacturing apparatus according to the present invention is:
In the vehicular lamp manufacturing apparatus for welding the front lens and the lamp body by heating the planned welding surface of the front lens and the planned welding surface of the lamp body and then pressing the two welding planned surfaces together,
A lens holding jig for holding the front lens, a body holding jig for holding the lamp body, and a heat generation in which a lens heating surface and a body heating surface having substantially the same surface shape as the two welding planned surfaces are formed on both side surfaces. A body, and is configured to perform the heating by placing the two welding scheduled surfaces close to the lens heating surface and the body heating surface for a predetermined time,
Ceramic coating is applied to the lens heating surface and body heating surface on both sides of the heating element ,
The ceramic coating is made of ceramics that emits infrared rays having a peak wavelength of 2.7 to 3.5 μm by heat generation, and is formed by ceramic spraying .
[0011]
As long as the “ceramic coating” is applied to at least the lens heating surface and the body heating surface, the ceramic coating may or may not be applied to other portions on the both side surfaces.
[0012]
[Effects of the invention]
As shown in the above configuration, the vehicular lamp manufacturing apparatus according to the present invention heats the planned welding surface of the front lens and the planned welding surface of the lamp body, and then presses both the planned welding surfaces to each other. The lens and the lamp body are configured to be welded, and both the surfaces to be welded are configured to perform the heating by placing them close to the lens heating surface and the body heating surface of the heating element for a predetermined time. Therefore, the following effects can be obtained.
[0013]
In other words, when heating the planned welding surface of the front lens and the planned welding surface of the lamp body, the both welding planned surfaces are not placed in contact with the lens heating surface and the body heating surface, but are disposed close to each other. Even if the front lens or lamp body has dimensional variations or the manufacturing equipment has dimensional accuracy errors, the lens heating surface and body heating surface do not come into contact with both planned welding surfaces. The part is not deformed and foam burrs are not generated on both sides. And the foam burr generated in the vehicle lamp as a finished product is only generated on both sides of the welding surface by pressing the two surfaces to be welded together. It becomes so small that it is hardly noticeable even when observed.
[0014]
Further, since both the surfaces to be welded and the lens heating surface and body heating surface of the heating element are not in contact with each other, in order to promote mold release that has been regularly performed on these lens heating surface and body heating surface. This eliminates the need for a surface treatment, thereby facilitating maintenance. Further, since the conventional threading phenomenon does not occur, it is possible to prevent the threading part from remaining in the lamp chamber of the vehicular lamp after welding and causing an appearance defect. .
[0015]
Moreover, since the vehicular lamp manufacturing apparatus according to the present invention has the ceramic coating on the lens heating surface and the body heating surface on both side surfaces of the heating element, the following effects can be obtained.
[0016]
That is, the heating element radiates heat energy with a wide wavelength distribution by the heat generation. Moreover, the wavelength distribution differs depending on the heat generation temperature. On the other hand, the front lens and the lamp body to be heated are made of synthetic resin, and the thermal energy that is easily absorbed by these is limited to that in the mid-infrared wavelength region. On the other hand, ceramics has the property of radiating heat energy secondarily by receiving heat energy from the outside, and at that time, has the property of radiating heat energy in a specific infrared wavelength region.
[0017]
Therefore, by applying a ceramic coating on the lens heating surface and body heating surface, heat energy in the mid-infrared wavelength region, which is easily absorbed by the front lens and the lamp body, can be radiated to the planned welding surfaces of the front lens and the lamp body. This makes it possible to shorten the heating time.
[0018]
Thus, according to the present invention, in the vehicular lamp manufacturing apparatus that welds the front lens and the lamp body by hot plate welding, it is possible to perform the welding efficiently without greatly impairing the appearance around the welding surface. .
[0019]
Moreover, in the present invention, the ceramics constituting the “ceramic coating” is made of ceramics that emits infrared rays having a peak wavelength of 2.7 to 3.5 μm due to heat generation . Heat energy in a high wavelength region can be secondarily emitted.
[0020]
Furthermore, in the present invention, since the “ceramic coating” is formed by ceramic spraying , the following effects can be obtained .
[0021]
That is, when the film thickness of the ceramic coating increases, the heating effect decreases due to the heat insulating action, and cracks due to the difference in the coefficient of thermal expansion from the base material (heating element) tend to occur. Since it is possible to easily form a thin ceramic coating, it is possible to prevent a reduction in heating effect and occurrence of cracks. In addition, by employing ceramic spraying, it is possible to easily form a ceramic coating even when the surface shapes of the lens heating surface and the body heating surface change three-dimensionally.
[0022]
At the time of the heating, both welding scheduled surfaces are arranged close to the lens heating surface and the body heating surface, but the intervals at this time are values of 5 mm or less (for example, 0.3 to 3.0 mm). Alternatively, it is preferable to set the thickness to 0.5 to 1.0 mm in order to perform welding efficiently and in a short time.
[0023]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[0024]
FIG. 1 is an exploded cross-sectional perspective view showing a vehicular lamp manufacturing apparatus according to an embodiment of the present invention, and FIG. 2 shows a vehicular lamp 10 manufactured by the manufacturing apparatus in an upwardly arranged state. It is a sectional side view.
[0025]
Before describing the manufacturing apparatus, the vehicle lamp 10 will be described first.
[0026]
As shown in FIG. 2, this vehicular lamp 10 is a sign lamp such as a tail lamp, and a light source bulb 12 is inserted on a lamp reference axis Ax extending in a vertical direction (the lamp is a front-rear direction, the same applies hereinafter). The lamp body 14 and a front lens 16 welded to the lamp body 14 by hot plate welding are provided.
[0027]
The front lens 16 is made of a thermoplastic resin material such as PMMA or PC. On the outer peripheral edge of the front lens 16, a seal leg 16a protruding downward is formed over the entire circumference. On the other hand, the lamp body 14 is formed of a thermoplastic resin material such as AAS or ABS. At the front end opening of the lamp body 14, a protrusion 14a is formed over the entire circumference so as to face the seal leg 16a. And the hot plate welding of the front lens 16 and the lamp body 14 is performed between the front end surface 16b of the seal leg 16a and the front end surface 14b of the projection 14a.
[0028]
As shown in FIG. 1, the manufacturing apparatus according to this embodiment includes a lens holding jig 112, a body holding jig 114, and a heating element 116.
[0029]
The lens holding jig 112 is formed with a lens mounting recess 112a having substantially the same shape as the surface of the front lens 16, and holds the front lens 16 in the lens mounting recess 112a. On the other hand, the body holding jig 114 is formed with a body mounting recess 114a having substantially the same shape as the back surface of the lamp body 14, and holds the lamp body 14 in the body mounting recess 114a.
[0030]
The heating element 116 has a substantially plate-like metal member 118 embedded with a cartridge heater 120 as a heat source. On the upper surface 116a of the heating element 116, a lens heating surface 116b having substantially the same surface shape as the planned welding surface 16b of the front lens 16 (that is, the front end surface of the seal leg 16a) is formed. A ceramic coating C is applied to the lens heating surface 116b and its peripheral region on the upper surface 116a. Further, a body heating surface 116d having substantially the same surface shape as the planned welding surface 14b of the lamp body 14 (that is, the front end surface of the protrusion 14a) is formed on the lower surface 116c of the heating element 116. A ceramic coating C is applied to the body heating surface 116d and its peripheral region on the lower surface 116c of the heating element 116.
[0031]
The ceramic coating C on the upper and lower surfaces 116a and 116c of the heating element 116 is made of ceramics (for example, Si oxide, Al oxide, etc.) that emits infrared rays having a peak wavelength of 2.7 to 3.5 μm due to heat generation. . And this ceramic coating C is formed by ceramic spraying, The film thickness is set to 0.5-3.0 mm.
[0032]
FIG. 4 is a graph showing the wavelength distribution of the thermal energy radiated from the heating element 116 and the thermal energy radiated secondarily from the surface of the ceramic coating C.
[0033]
As shown in the figure, the wavelength distribution of the heat energy radiated from the heating element 116 varies depending on the heat generation temperature, but is easily absorbed by the front lens 16 and the lamp body 14 made of synthetic resin from the surface of the ceramic coating C. Thermal energy is secondarily radiated with a wavelength distribution peaking at infrared rays (2.7 to 3.5 μm). Thereby, the heat energy absorption efficiency of the front lens 16 and the lamp body 14 is increased.
[0034]
FIG. 3 is a process diagram showing in detail the state of hot plate welding between the front lens 16 and the lamp body 14 by the manufacturing apparatus according to the present embodiment, with respect to part III in FIG.
[0035]
First, as shown in FIG. 2A, a heating element 116 is inserted between a lens holding jig 112 holding the front lens 16 and a body holding jig 114 holding the lamp body 14 therebetween. Arrange vertically. At that time, the heating element 116 energizes the cartridge heater 120 to heat the metal member 118 to about 500 to 800 ° C. in advance. The heating element 116 and the front lens 16 are disposed close to each other so that the lens heating surface 116b and the planned welding surface 16b are separated by a minute distance d1 (0.5 <d1 <1.0 mm). The body 116 and the lamp body 14 are disposed close to each other so that the body heating surface 116d and the planned welding surface 14b are separated by a minute distance d2 (0.5 <d2 <1.0 mm). In this state, it is left for a predetermined time (about 10 to 25 seconds), and by the thermal energy of infrared rays radiated from the heating element 116 through the two ceramic coatings C, the vicinity of the planned welding surface 16b of the front lens 16 and the lamp body. The vicinity of the welding planned surface 14b is softened and melted.
[0036]
Next, as shown in FIG. 5B, after removing the heating element 116 from between the lens holding jig 112 and the body holding jig 114, the lens holding jig 112 is lowered and the front lens 16 is welded. The planned welding surface 16b and the planned welding surface 14b of the lamp body 14 are brought into contact with each other, and the lens holding jig 112 is lowered by a minute amount so that the welding planned surfaces 16b and 14b are pressed against each other. 14b are securely welded.
[0037]
Then, as shown in FIG. 4C, the vehicular lamp 10 in which the front lens 16 and the lamp body 14 have been welded by the above-described welding has a seal leg 16a of the front lens 16 and a protrusion 14a of the lamp body 14. Foaming burrs P are generated on both sides of the weld surface, and the foaming burrs P are generated by the above-mentioned pressure contact, and the amount of protrusion is very small.
[0038]
As described above in detail, the vehicular lamp manufacturing apparatus according to the present embodiment heats the planned welding surface 16b of the front lens 16 and the planned welding surface 14b of the lamp body 14, and then both the planned welding surfaces 16b and 14b. The front lens 16 and the lamp body 14 are welded to each other by pressure-contacting each other, but both the planned welding surfaces 16b and 14b are connected to the lens heating surface 116b and the body heating surface 114b of the heating element 116. Since the above-described heating is performed by arranging them close to each other for a predetermined time, the following effects can be obtained.
[0039]
That is, when the planned welding surfaces 16b, 14b of the front lens 16 and the planned welding surfaces 16b, 14b of the lamp body 14 are heated, both the planned welding surfaces 16b, 14b are brought into contact with the lens heating surface 116b and the body heating surface 114b. Since the front lens 16 and the lamp body 14 are not close to each other but are arranged close to each other, even if there is a dimensional variation or there is a dimensional accuracy error in the manufacturing apparatus, both the lens heating surface 116b and the body heating surface 114b are welded together. The planned surfaces 16b and 14b do not come into contact with each other, and therefore, a portion near the planned welding surfaces 16b and 14b is not deformed and foam burrs are not generated on both sides thereof. The foam burr P generated in the vehicular lamp 10 as a finished product is only generated on both sides of the welding surface by pressing the two welding scheduled surfaces 16b and 14b together. Even if this is observed from the outside of the lamp, it becomes so small that it is hardly noticeable.
[0040]
In addition, since both the surfaces to be welded 16b and 14b are not in contact with the lens heating surface 116b and the body heating surface 114b of the heating element 116, the lens heating surface 116b and the body heating surface 114b are regularly provided. The conventional surface treatment for promoting mold release is not required, thereby facilitating maintenance. Further, since the conventional threading phenomenon does not occur, the threading part does not remain in the lamp chamber of the vehicular lamp after welding and no appearance defect occurs.
[0041]
Moreover, the vehicular lamp manufacturing apparatus according to the present embodiment has the following effects because the ceramic coating C is applied to the lens heating surface 116b and the body heating surface 114b on both side surfaces of the heating element 116. Obtainable.
[0042]
That is, the heating element 116 radiates heat energy with a wide wavelength distribution by the heat generation. Moreover, the wavelength distribution differs depending on the heat generation temperature. On the other hand, the front lens 16 and the lamp body 14 to be heated are made of synthetic resin, and the thermal energy that is easily absorbed by these is limited to that in the mid-infrared wavelength region. On the other hand, ceramics has the property of radiating heat energy secondarily by receiving heat energy from the outside, and at that time, has the property of radiating heat energy in a specific infrared wavelength region.
[0043]
Therefore, as in the present embodiment, by applying the ceramic coating C to the lens heating surface 116b and the body heating surface 114b, the thermal energy in the mid-infrared wavelength region that is easily absorbed by the front lens 16 and the lamp body 14 is transferred to the front lens. 16 and the planned welding surfaces 16b and 14b of the lamp body 14 can be radiated, thereby shortening the heating time.
[0044]
As described above, according to the present embodiment, in the vehicular lamp manufacturing apparatus that welds the front lens and the lamp body by hot plate welding, it is possible to efficiently perform the welding without greatly impairing the appearance around the welding surface. it can.
[0045]
In particular, in the present embodiment, as the ceramic constituting the ceramic coating C, a ceramic that secondarily emits infrared light having a peak wavelength of 2.7 to 3.5 μm having high absorbability with respect to the front lens 16 and the lamp body 14 is selected. Therefore, the welding efficiency can be further improved.
[0046]
In addition, in the present embodiment, since the ceramic coating C is formed by ceramic spraying, the thickness of the ceramic coating C can be set thin, thereby reducing the heating effect due to the heat insulating action of the ceramic coating C and generating cracks. Can be prevented in advance. Further, by adopting ceramic spraying, even if the surface shapes of the lens heating surface 116b and the body heating surface 114b change three-dimensionally instead of two-dimensionally as in this embodiment, the ceramics can be easily formed. The coating C can be formed.
[0047]
Further, in the present embodiment, when both the welding scheduled surfaces 16b and 14b are heated, they are disposed close to the lens heating surface 116b and the body heating surface 114b at a minute interval d1 and d2 of 0.5 to 1.0 mm. Therefore, welding can be performed in a short time with high thermal efficiency. In addition, even if these minute intervals d1 and d2 are outside the range of 0.5 to 1.0 mm and have a value of 5 mm or less, it is possible to sufficiently soften and melt both welding scheduled surfaces 16b and 14b. .
[0048]
In this embodiment and each modified example, the case where the vehicular lamp 10 to be welded is a marker lamp has been described. However, by adopting the configuration of the present embodiment also for other types of vehicular lamps. The same effect as this embodiment can be obtained.
[Brief description of the drawings]
FIG. 1 is an exploded cross-sectional perspective view showing a vehicular lamp manufacturing apparatus according to an embodiment of the present invention. FIG. 2 is a side cross-sectional view showing a vehicular lamp manufactured by the manufacturing apparatus arranged upward. FIG. 3 is a process chart showing in detail the state of hot plate welding between the front lens and the lamp body by the above manufacturing apparatus for the portion III in FIG.
FIG. 4 is a graph showing the wavelength distribution of heat energy emitted from the heating element of the manufacturing apparatus and heat energy emitted secondarily from the surface of the ceramic coating. FIG. 5 shows a conventional example, similar to FIG. Figure [Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Vehicle lamp 12 Light source bulb 14 Lamp body 14a Projection part 14b Planned welding surface (tip surface)
16 Front lens 16a Seal leg 16b Planned welding surface (tip surface)
112 Lens holding jig 112a Lens mounting recess 114 Body holding jig 114a Body mounting recess 116a Upper surface 116b Lens heating surface 116c Lower surface 116d Body heating surface 118 Metal member 120 Cartridge heater Ax Lamp reference axis C Ceramic coating d1, d2 Minute interval P Foaming Bari

Claims (2)

In the vehicular lamp manufacturing apparatus for welding the front lens and the lamp body by heating the planned welding surface of the front lens and the planned welding surface of the lamp body and then pressing the two welding planned surfaces together,
A lens holding jig for holding the front lens, a body holding jig for holding the lamp body, and a heat generation in which a lens heating surface and a body heating surface having substantially the same surface shape as the two welding planned surfaces are formed on both side surfaces. A body, and is configured to perform the heating by placing the two welding scheduled surfaces close to the lens heating surface and the body heating surface for a predetermined time,
Ceramic coating is applied to the lens heating surface and body heating surface on both sides of the heating element ,
An apparatus for manufacturing a vehicular lamp , wherein the ceramic coating is made of ceramics that emits infrared rays having a peak wavelength of 2.7 to 3.5 µm by heat generation, and is formed by ceramic spraying . Distance between the lens heating surface and the body heating surface and the both intended welding surface during the heating is set respectively to the following values 5 mm, manufacture of the vehicular lamp according to claim 1, wherein the apparatus.

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