JP4318503B2 - 車両用灯具とその製造方法 - Google Patents

車両用灯具とその製造方法 Download PDF

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Publication number
JP4318503B2
JP4318503B2 JP2003286456A JP2003286456A JP4318503B2 JP 4318503 B2 JP4318503 B2 JP 4318503B2 JP 2003286456 A JP2003286456 A JP 2003286456A JP 2003286456 A JP2003286456 A JP 2003286456A JP 4318503 B2 JP4318503 B2 JP 4318503B2
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Japan
Prior art keywords
lens
contact
lamp body
seal leg
lamp
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
JP2003286456A
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English (en)
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JP2005056688A (ja
Inventor
千春 松永
三千彦 鈴木
富士彦 杉山
一廣 山▲崎▼
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Koito Manufacturing Co Ltd
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Koito Manufacturing Co Ltd
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Publication date
Application filed by Koito Manufacturing Co Ltd filed Critical Koito Manufacturing Co Ltd
Priority to JP2003286456A priority Critical patent/JP4318503B2/ja
Priority to US10/909,731 priority patent/US7118250B2/en
Priority to DE200410037517 priority patent/DE102004037517B4/de
Publication of JP2005056688A publication Critical patent/JP2005056688A/ja
Application granted granted Critical
Publication of JP4318503B2 publication Critical patent/JP4318503B2/ja
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1677—Laser beams making use of an absorber or impact modifier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1687—Laser beams making use of light guides
    • B29C65/169—Laser beams making use of light guides being a part of the joined article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/116—Single bevelled joints, i.e. one of the parts to be joined being bevelled in the joint area
    • B29C66/1162—Single bevel to bevel joints, e.g. mitre joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1222—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a lapped joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • B29C66/1224—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • B29C66/1226—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least one bevelled joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • B29C66/122—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section
    • B29C66/1226—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least one bevelled joint-segment
    • B29C66/12261—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least one bevelled joint-segment the two joint-segments being bevelled, e.g. the two joint-segments forming a V
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove joints
    • B29C66/1244—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue
    • B29C66/12441—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue being a single wall
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove joints
    • B29C66/1244—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue
    • B29C66/12449—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue being asymmetric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove joints
    • B29C66/1246—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove
    • B29C66/12463—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove being tapered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • B29C66/124—Tongue and groove joints
    • B29C66/1246—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove
    • B29C66/12469—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove being asymmetric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/128—Stepped joint cross-sections
    • B29C66/1282—Stepped joint cross-sections comprising at least one overlap joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • B29C66/128—Stepped joint cross-sections
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    • B29C66/12841—Stepped joint cross-sections comprising at least one butt joint-segment comprising at least two butt joint-segments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/7334—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being glossy or matt, reflective or refractive
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S43/00—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights
    • F21S43/50—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by aesthetic components not otherwise provided for, e.g. decorative trim, partition walls or covers
    • F21S43/51—Attachment thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/116—Single bevelled joints, i.e. one of the parts to be joined being bevelled in the joint area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/0026—Transparent
    • B29K2995/0027—Transparent for light outside the visible spectrum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/747—Lightning equipment

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Description

本発明はランプボディにレンズをレーザ溶着した車両用灯具及び製造方法に関するものである。
自動車のヘッドランプ等の車両用灯具（以下、ランプと称する）は、ランプボディの前面開口部にレンズを取着してランプ室を形成し、このランプ室内に光源としてのバルブやリフレクタを配設した構成となっている。ランプボディの前面開口部にレンズを取着する構成としては、レンズをランプボディにレーザ溶着等によって一体化する技術がある。このようなランプとして、特許文献１に記載の技術では、レンズに設けたシール脚の外側面に、ランプボディとの当接方向に対して斜め方向から入射するレーザ光を溶着面に導くレーザ光受け面を突出形成した構成となっている。
すなわち、図１０に示すように、レンズ２のシール脚２３Ａの先端に設けた当接面２３１Ａと、ランプボディ１Ａの周壁部１２Ａに設けた当接面１２１Ａとをそれぞれ当接してレーザ溶着を行っており、シール脚部２３Ａの先端部には外側に突出させたレーザ光受け面２５Ａを形成し、レンズ２Ａの外側面からレーザ光受け面２５Ａに投射したレーザ光Ｌをランプボディ１Ａの当接面１２１Ａに導くことでレンズ２Ａとランプボディ１Ａの両当接面１２１Ａ，２３１Ａをレーザ溶着する。このように構成することで、特許文献１にも記載されているように、レーザ光受け面を設けていない従来構成のようにレーザ光をレンズのシール脚部内を当接方向に沿って透過させながら当接面に投射してレーザ溶着を行う場合に比較して、当接面に投射されるレーザ光がレンズ内を透過する光路長を短くし、当接面におけるレーザ光のエネルギの低減を抑制して好適な溶着を行うことが可能となる。
特開２００１−２４３８１１号公報
特許文献１の技術では、レーザ光受け面をレンズのシール脚部の外側面に突出形成しているため、レンズを前方から見たときにレンズの周縁部にレーザ光受け面が突出した状態の外観となり、レンズの外形寸法、すなわちランプの外形寸法が大きくなる。また、レンズとランプボディの溶着面はレンズを透して前方から見ると暗黒部として見えることになるが、レーザ光受け面を形成することによってレーザ溶着面の幅寸法（シール脚の厚さ方向の寸法）が大きくなるため、レンズの外縁部に幅の大きな暗黒部が見えるようになり、外観上の見栄えが低下してしまう。また、シール脚の外側面に突出するレーザ光受け面によってレンズを成形する際の金型構造が複雑になり、コスト高になるという問題も生じる。
本発明の目的は、レーザ溶着面の幅寸法を低減し、見栄えを向上したランプとその製造方法を提供するものである。
本発明は、ランプボディとレンズとを当接させて両当接面をレーザ溶着した車両用灯具において、レンズは外側面に沿って前記当接方向に延びるほぼ均一な肉厚のシール脚部を備え、当該シール脚部の先端面は当該レンズの外側面よりも外側方向に突出されておらず内側に向けて傾斜した当接面として構成され、ランプボディは外側面に沿って外方に突出され、外方に向けて徐々に肉厚が低減されるテーパ状のフランジ部を有し、当該フランジ部の表面が外側に向けて傾斜した当接面として構成されていることを特徴とする。
本発明の製造方法は、ランプボディとレンズとを当接させて両当接面をレーザ溶着した車両用灯具の製造方法であって、前記レンズは外側面に沿って前記当接方向に延びるほぼ均一な肉厚のシール脚部を備え、当該シール脚部の先端面は当該レンズの外側面よりも外側方向に突出されておらず内側に向けて傾斜した当接面として構成され、前記ランプボディは外側面に沿って外方に突出され、外方に向けて徐々に肉厚が低減されるテーパ状のフランジ部を有し、当該フランジ部の表面が外側に向けて傾斜した当接面として構成され、前記シール脚部を前記フランジ部に対して加圧して前記フランジ部を変形させ、前記両当接面を密着させた状態でレーザ溶着を行うことを特徴とする。
本発明によれば、レーザ溶着面はレンズの外側面よりも外方に突出されていないため、レンズを透して前方から見たときのレンズ周縁部の暗黒部の幅を小さくし、ランプの見栄えを向上する。また、レーザ溶着面はレンズとランプボディの当接方向に対して傾斜しているため、レーザ溶着面の面積を大きくでき、強固な溶着が可能になる。特に、レンズは外側面に沿って当接方向に延びるほぼ均一な肉厚のシール脚部を備え、当該シール脚部の先端面が当接面として構成されていることで、当接面をシール脚部の肉厚の範囲内に制限でき、見栄えの向上に有効となる。また、ランプボディは外側面に沿って外方に突出され、外方に向けて徐々に肉厚が低減されるテーパ状のフランジ部を有し、当該フランジ部の表面が当接面として構成されていることで、レンズをランプボディに当接させたときに生じるフランジ部の変形によって両当接面の密着性を高め、溶着品質を向上することが可能になる。
本発明の製造方法によれば、ランプボディは外側面に沿って外方に突出され、外方に向けて徐々に肉厚が低減されるテーパ状のフランジ部を有し、当該フランジ部の表面が当接面として構成されており、レーザ溶着時にレンズからランプボディに加えられる加圧力によってフランジ部を変形し、この変形によって両当接面の密着性を高めることができるので、レーザ溶着品質を向上することが可能になる。
本発明において、フランジ部はシール脚部から加圧力を受けたときに外方に突出された部分がランプボディ側に向けて変形されてレンズとランプボディの両当接面が密着するようにする。特に、レンズの当接面の傾斜角度がランプボディの当接面の傾斜角度よりも大きいときにはフランジ部の変形によって両当接面の密着性が高められる。
次に、本発明の実施例を図面を参照して説明する。図１は本発明を自動車のテールランプ、特にテール＆ストップランプＴＳＬ、バックアップランプＢＵＬを一体化したリアコンビネーョシンランプＲＣＬに適用した参照例としての実施例１の部分分解斜視図、図２は組立状態のＡ−Ａ線に沿う断面図である。ランプボディ１は背面部１１と、この背面部の周縁に沿って立設された周壁部１２とで容器状に形成されており、カーボンブラック等のレーザ光吸収材を含んだＡＳＡ（アクリロニトリル・スチレン・アクリルゴム）等の樹脂成形によって形成されている。前記ランプボディ１の背面部１１の内面には立壁状のシェード１３が形成され、このシェード１３によってテール＆ストップランプＴＳＬとバックアップランプＢＵＬが区画される。また、前記背面部１１及び周壁部１２の各内面にはアルミニウム蒸着が施されている。ただし、後述するように周壁部１２のうち、レンズを溶着する部分の表面には蒸着を行わないようにする。また、前記ランプボディ１の背面部１１には各ランプＴＳＬ，ＢＵＬに対応してバルブ取付穴１４，１５が開口されており、テール＆ストップバルブ３、バックアップバルブ４がそれぞれバルブソケット５，６により取り付けられている。
前記ランプボディ１には、正面開口を覆うようにレンズ２が溶着により一体的に取着されている。前記レンズ２は全体が赤色をしたテール＆ストップレンズ２１と、テール＆ストップレンズ２１の一部領域内に配設された白色をしたバックアップレンズ２２とがＰＣ等の樹脂の二色成形法等によって一体的に形成されている。そして、このレンズ２は周縁に沿って壁状のシール脚部２３が形成されており、このシール脚部２３の先端において前記ランプボディ１の周壁部１２の先端にレーザ溶着によって溶着され、ランプボディ１に一体化されるとともに、ランプボディ１とレンズ２との間を封止する構成とされている。
図３は前記ランプボディ１とレンズ２の溶着部分を示す図２のＢ部の拡大断面図である。ランプボディ１の周壁部１２は光軸方向と平行に向けてほぼ均一な肉厚で立設されており、その先端面は光軸方向に対してほぼ４５°で外側に向けて傾斜した当接面１２１として形成されている。同様にレンズ２のシール脚部２３も光軸方向と平行に向けてほぼ均一な肉厚で立設されており、その先端面は同じく光軸方向に対してほぼ４５°の角度で内側に向けて傾斜した当接面２３１として形成されている。そして、前記ランプボディ１とレンズ２とが光軸方向に突き合わされ、周壁部１２の当接面１２１とシール脚部２３の当接面２３１とが光軸方向に当接されて密接状態とされ、その上で、密接状態とされた当接面に対してレンズ２の外面側から集光状態のレーザ光が投射され、ランプボディ１とレンズ２とは当接面１２１，２３１において互いに溶融されて溶着（溶着面を符号Ｘで示す）され、レンズ２がランプボディ１に一体化されている。なお、この実施例１では周壁部１２にはシール脚部２３の位置決めを行うために先端部の肉厚がシール脚部２３よりも若干厚くされており、シール脚部２３の内面側と外面側にそれぞれ突条１２２，１２３が形成されているが、これは特に必要とされるものではない。
前記ランプボディ１とレンズ２の当接面１２１，２３１における溶着に際しては、図４（ａ）に示すように、樹脂成形し、かつ所要の表面にアルミニウム蒸着したランプボディ１を周壁部１２の当接面１２１が上方を向くように治具下型ＤＫにセットする。一方、図外の位置決め治具によってレンズ２をランプボディ１上に載置し、シール脚部２３の当接面２３１を周壁部１２の当接面１２１上に当接させる。そして、図４（ｂ）のように、治具上型ＵＫを下降してレンズ２を下方に押圧し、レンズ２をランプボディ１に対して所定の圧力で加圧する。そして、この状態において、図４（ｃ）のように、レンズ２の外側から、正確にはシール脚部２３の外側面の外方から密接状態にある当接面１２１，２３１に向けて垂直方向にレーザ光Ｌを投射する。レーザ光Ｌの投射により、レーザ光エネルギはまずランプボディ１に含まれているレーザ光吸収材によって吸収され、ランプボディ１の当接面１２１が発熱し、溶融される。また、この熱は密接されているレンズ２の当接面２３１にも伝達され、レンズ２の当接面２３１が溶融される。これにより、ランプボディ１とレンズ２の各当接面１２１，２３１が相溶状態となり、冷却固化したときに両者が接合されることになる。
このとき、図５に示すように、レンズ２に投射されたレーザ光Ｌはシール脚部２３の外側面からレンズ２内に入射される際に屈折されて当接面１２１，２３１に投射されるため、レンズ２における光の屈折率を考慮して、シール脚部２３の外側面に垂直な方向に対して４５°よりも若干大きな角度θで入射させるようにする。これにより、入射されたレーザ光Ｌは屈折された後に当接面１２１，２３１に対して垂直に投射されることになり、レーザ光が投射面１２１，２３１に対して斜め方向から投射される場合に比較してレーザ光のエネルギが溶着に有効に機能するようになり、強固な溶着が可能になる。
以上のように構成したランプＲＣＬでは、当該ランプＲＣＬを前面側から見たときに、レンズ２のシール脚部２３の当接面２３１がランプボディ１との溶着によってレンズ２を透してレンズ周縁部において暗黒色に見えることになるが、レンズ２のシール脚部２３には特許文献１の技術のようにレンズ２の外形寸法となる外側面よりも外側方向に突出する部分が存在していないため、レンズ２の当接面２３１、換言すれば溶着面Ｘはシール脚部２３の肉厚の範囲内で形成されることになるため、暗黒部の幅は最大でもレンズ脚部２３の肉厚寸法よりも大きくなることはなく、ランプの見栄えを向上することになる。さらに、各当接面１２１，２３１はランプボディ１とレンズ２の光軸方向、換言すれば周壁部１２とシール脚部２３の立設方向に対して傾斜しているため、これらの肉厚寸法に対して溶着面Ｘの面積を大きくでき、強固な溶着が可能になる。
ここで、ランプボディ１及びレンズ２の各当接面１２１，２３１が当接方向に対して傾斜している角度は１５°以上７５°以下にすることが好ましい。１５°よりも小さいと当接面に対して投射されるレーザ光が当接面に対して垂直に投射させることが困難になり、レンズ入射面でのレーザ光の反射が多くなり所定量のエネルギが吸収されずに溶着不足になる。また、７５°よりも大きいと当接面の傾斜が鋭角になりすぎ、樹脂成形が困難になるとともに両当接面を当接させた状態で加圧するとレンズとランプボディとの間に楔作用によって発生するずれ方向の力が大きくなり、高精度に位置合わせした溶着が困難になる。
なお、前記実施例１では、当接面を完全に傾斜面として構成しているが、図６（ａ）に示すように、当接面の内側と外側のそれぞれに沿う領域に当接方向に垂直な面部１２４，１２５と２３２，２３３を形成し、或いは図６（ｂ）のように、当接面の外側に沿う領域に当接方向に垂直な面部１２６と２３４を形成するようにしてもよい。このような面部を設けることで、両当接面を当接したときに両当接面間に滑りが生じてランプボディ１とレンズ２との位置ずれをさらに効果的に防止することができる。
図７は本発明の他の参照例としての実施例２を示す図であり、実施例１の図３に対応する拡大断面図である。実施例２では同図に示すレンズ２の周方向の一部においてはシール脚部は形成されておらず、この部分にはレンズ２の内面側に断面が三角形状をした突条部２４を形成し、この突条部２４のテーパ面２４１を当接面として構成したものである。この実施例２ではランプボディ１に設けたた当接面１２１は実施例１と同様に光軸方向に対してほぼ４５°で外側に向けて傾斜した当接面として形成されており、これに対応して前記レンズ２の突条部２４に設けた当接面２４１は光軸方向に対してほぼ４５°で内側に向けて傾斜した当接面として形成されている。そして、前記ランプボディ１とレンズ２とが光軸方向に突き合わされ、周壁部１２の当接面１２１と突条部２４の当接面２４１とが光軸方向に当接されて密接状態とされる。その上で、これら当接面１２１，２４１に対してレンズの外面側から集光状態のレーザ光が投射されることで、両当接面１２１，２４１は溶融されて互いに溶着され、レンズ２がランプボディ１に一体化されることになる。
この実施例２では突条部２４におけるレンズ２の肉厚が薄くできるため、レンズ２の前面側からレーザ光を投射することも可能である。しかし、突条部２４の外側面からレーザ光を投射し、当該外側面でのレーザ光の屈折を利用することで、レーザ光を当接面１２１，２４１に対して垂直な方向から投射することが可能になり、レーザ光のエネルギ効率を高めて品質の高い溶着が可能になる。また、実施例２ではシール脚部を設けていないレンズに対しても好適な溶着が実現できるため、レンズの設計の自由度を高めてデザイン性が向上できる。
実施例２においても、実施例１と同様にランプを前面側から見たときに、レンズ２の周縁に設けた突条部２４の当接面２４１がランプボディ１と溶着されることによってレンズ２を透して暗黒色に見えることになるが、レンズ２には外側方向に突出する部分が存在していないため、前記暗黒部の幅を最小限の寸法に抑制することができ、見栄えを向上することができる。
図８は本発明の実施例３を示す図であり、実施例１の図３に対応する拡大断面図である。実施例３では、レンズ２は実施例１と同様にシール脚部２３を有しており、このシール脚部２３の先端面が傾斜した当接面２３１として形成されている。一方、ランプボディ１は周壁部１２の先端部に外方に突出され、かつ外方に向けて徐々に肉厚が低減されたテーパ状のフランジ部１２ａが形成されており、このフランジ部１２ａの表面が当接面１２１として形成されている。そして、このフランジ部１２ａの当接面１２１にレンズ２の当接面２３１が当接され、レーザ溶着が行われる。
実施例３では、実施例１，２と同様にレンズ２のシール脚部２３の外側面から所要の角度でレーザ光を投射することで、当該外側面での屈折によってレーザ光は当接面１２１，２３１に垂直方向に当接され、両当接面１２１，２３１を好適に溶着することが可能になる。また、レンズ２のシール脚部２３には外側方向に突出する部分が存在していないため、レンズ２の当接面２３１はシール脚部２３の肉厚の範囲内で形成されることになるため、暗黒部の幅は最大でもシール脚部２３の肉厚寸法よりも大きくなることはなく、ランプの見栄えを向上することになる。
また、実施例３では、仮に図９（ａ）のように、ランプボディ１やレンズ２の成形時の誤差によってレンズ２の当接面２３１とフランジ部１２ａの当接面１２１の角度が等しく形成されておらず、両当接面１２１，２３１を合わせたときに両者の間に隙間が生じたような場合でも、レーザ溶着に際してレンズ２をランプボディ１に向けて加圧しながら当接させる際に、図９（ｂ）のように、加圧力によってテーパ状をしたフランジ部１２ａが同図矢印のように変形されるため、両当接面１２１，２３１の密着性が高められ、レーザ溶着の溶着品質を向上することが可能になる。
本発明は前記各実施例で示したリアコンビネーションランプに限られるものではなく、レンズとランプボディとをレーザ溶着のように溶着して一体化するランプであれば同様に適用可能であることは言うまでもない。
実施例１のランプの部分分解斜視図である。 図１のＡ−Ａ線に沿う断面図である。 図２のＢ部の拡大断面図である。 実施例１のランプの溶着工程を説明する図である。 実施例１におけるレーザ溶着の作用を説明する図である。 実施例１の変形例の要部の断面図である。 実施例２の要部の断面図である。 実施例３の要部の断面図である。 実施例３におけるフランジ部の作用を説明する図である。 特許文献１の技術を説明する断面図である。
符号の説明
１ ランプボディ
２ レンズ
３ テール＆ストップバルブ
４ バックアップバルブ
５ バルブソケット
６ バルブソケット
１１ 背面部
１２ 周壁部
１３ シェード
２１ テール＆ストップレンズ
２２ バックアップレンズ部
２３ シール脚部
２４ 突条部
１２１ 当接面
２３１ 当接面
２４１ 当接面
ＲＣＬ リアコンビネーションランプ
ＴＳＬ テール＆ストップランプ
ＢＵＬ バックアップランプ

Claims (3)

  1. ランプボディとレンズとを当接させて両当接面をレーザ溶着した車両用灯具において、前記レンズは外側面に沿って前記当接方向に延びるほぼ均一な肉厚のシール脚部を備え、当該シール脚部の先端面は当該レンズの外側面よりも外側方向に突出されておらず内側に向けて傾斜した当接面として構成され、前記ランプボディは外側面に沿って外方に突出され、外方に向けて徐々に肉厚が低減されるテーパ状のフランジ部を有し、当該フランジ部の表面が外側に向けて傾斜した当接面として構成されていることを特徴とする車両用灯具。
  2. 前記フランジ部は前記シール脚部から加圧力を受けたときに外方に突出された部分がランプボディ側に向けて変形されて前記両当接面が密着することを特徴とする請求項１に記載の車両用灯具。
  3. ランプボディとレンズとを当接させて両当接面をレーザ溶着した車両用灯具の製造方法であって、前記レンズは外側面に沿って前記当接方向に延びるほぼ均一な肉厚のシール脚部を備え、当該シール脚部の先端面は当該レンズの外側面よりも外側方向に突出されておらず内側に向けて傾斜した当接面として構成され、前記ランプボディは外側面に沿って外方に突出され、外方に向けて徐々に肉厚が低減されるテーパ状のフランジ部を有し、当該フランジ部の表面が外側に向けて傾斜した当接面として構成され、前記シール脚部を前記フランジ部に対して加圧して前記フランジ部を変形させ、前記両当接面を密着させた状態でレーザ溶着を行うことを特徴とする車両用灯具の製造方法。
JP2003286456A 2003-08-05 2003-08-05 車両用灯具とその製造方法 Expired - Fee Related JP4318503B2 (ja)

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