JP5553155B2 - Vehicle lamp manufacturing method using laser welding - Google Patents

Vehicle lamp manufacturing method using laser welding Download PDF

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Publication number
JP5553155B2
JP5553155B2 JP2010131403A JP2010131403A JP5553155B2 JP 5553155 B2 JP5553155 B2 JP 5553155B2 JP 2010131403 A JP2010131403 A JP 2010131403A JP 2010131403 A JP2010131403 A JP 2010131403A JP 5553155 B2 JP5553155 B2 JP 5553155B2
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thermoplastic resin
lens
resin member
annular rib
resin lens
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JP2011258391A (en
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吉裕 財津
和晃 鉾田
辰也 梅山
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Stanley Electric Co Ltd
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Stanley Electric Co Ltd
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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
    • B29C66/301—Three-dimensional joints, i.e. the joined area being substantially non-flat
    • 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
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
    • B29C65/1661—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined scanning repeatedly, e.g. quasi-simultaneous laser 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
    • B29C65/78—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
    • B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
    • B29C65/782—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined
    • B29C65/7823—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint
    • B29C65/7829—Positioning the parts to be joined, e.g. aligning, indexing or centring by setting the gap between the parts to be joined by using distance pieces, i.e. by using spacers positioned between the parts to be joined and forming a part of the joint said distance pieces being integral with at least one of the parts to be joined
    • 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
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/302—Particular design of joint configurations the area to be joined comprising melt initiators
    • B29C66/3022—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined
    • B29C66/30223—Particular design of joint configurations the area to be joined comprising melt initiators said melt initiators being integral with at least one of the parts to be joined said melt initiators being rib-like
    • 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
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/542—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining hollow covers or hollow bottoms to open ends of container bodies
    • 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
    • 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
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/863—Robotised, e.g. mounted on a robot arm
    • 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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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Health & Medical Sciences (AREA)
  • Electromagnetism (AREA)
  • Toxicology (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Description

本発明は、車両用灯具製造方法に係り、特にレーザー溶着を用いた車両用灯具製造方法に関する。   The present invention relates to a vehicular lamp manufacturing method, and more particularly to a vehicular lamp manufacturing method using laser welding.

従来、レーザー光に対し透過性を有する熱可塑性樹脂製レンズとレーザー光に対し吸収性を有する熱可塑性樹脂製部材とをレーザー溶着するレーザー溶着方法が知られている（例えば、特許文献１参照）。   Conventionally, a laser welding method is known in which a thermoplastic resin lens that is transparent to laser light and a thermoplastic resin member that is absorbent to laser light are laser-welded (see, for example, Patent Document 1). .

図８に示すように、特許文献１に記載のレーザー溶着方法においては、熱可塑性樹脂製レンズ２１０表面の外周部全周を走査するレーザー光Ｒａｙが、熱可塑性樹脂製レンズ２１０を透過し、当該熱可塑性樹脂製レンズ２１０が当接した熱可塑性樹脂製部材２２０を照射し、両者を溶融することで、レーザー溶着が行われる。   As shown in FIG. 8, in the laser welding method described in Patent Document 1, laser light Ray that scans the entire outer periphery of the surface of the thermoplastic resin lens 210 passes through the thermoplastic resin lens 210, and Laser welding is performed by irradiating the thermoplastic resin member 220 with which the thermoplastic resin lens 210 abuts and melting both of them.

特開２００５−３３９８７３号公報JP 2005-339873 A

しかしながら、上記特許文献１に記載のレーザー溶着方法においては、熱可塑性樹脂製レンズ２１０表面の外周部全周を走査し、その全周にわたりレーザー溶着を行うことが可能であるものの、熱可塑性樹脂製レンズ２１０の熱可塑性樹脂製部材２２０に対する沈み込み量Ｗ（図９（ａ）、図９（ｂ）参照）を制御することが考慮されていないために、沈み込み量Ｗが小さい場合には溶着強度が不足し、一方、沈み込み量Ｗが大きい場合には樹脂がはみだしてバリが発生し外観不良となる、という問題がある。   However, in the laser welding method described in Patent Document 1, it is possible to scan the entire circumference of the outer periphery of the surface of the thermoplastic resin lens 210 and perform laser welding over the entire circumference. Since it is not considered to control the sinking amount W (see FIGS. 9A and 9B) of the lens 210 with respect to the thermoplastic resin member 220, welding is performed when the sinking amount W is small. On the other hand, when the strength is insufficient and the sinking amount W is large, there is a problem that the resin protrudes and burrs are generated, resulting in poor appearance.

本発明は、このような事情に鑑みてなされたものであり、熱可塑性樹脂製レンズ表面の外周部全周を走査し、その全周にわたりレーザー溶着を行うことに起因する熱可塑性樹脂製部材に対する熱可塑性樹脂製レンズの沈み込み量を制御することが可能なレーザー溶着を用いた車両用灯具製造方法を提供することを目的とする。   The present invention has been made in view of such circumstances, and is directed to a thermoplastic resin member caused by scanning the entire outer periphery of a thermoplastic resin lens surface and performing laser welding over the entire periphery. It is an object of the present invention to provide a method for manufacturing a vehicular lamp using laser welding capable of controlling the sinking amount of a thermoplastic resin lens.

上記課題を解決するため、請求項１に記載の発明は、レーザー光に対し透過性を有する熱可塑性樹脂製レンズとレーザー光に対し吸収性を有する熱可塑性樹脂製部材とがレーザー溶着された車両用灯具を製造する方法において、前記熱可塑性樹脂製レンズと前記熱可塑性樹脂製部材とを加圧し互いに当接させた状態で保持する保持工程と、前記熱可塑性樹脂製レンズを透過して前記熱可塑性樹脂製レンズ裏面の外周部が当接した前記熱可塑性樹脂製部材を照射し、前記熱可塑性樹脂製部材とこれに当接した前記熱可塑性樹脂製レンズとを溶融して接合するように、前記熱可塑性樹脂製レンズ表面の外周部全周にレーザー光を走査する走査工程と、を含んでおり、前記熱可塑性樹脂製レンズには、当該熱可塑性樹脂製レンズが前記熱可塑性樹脂製部材に対し沈み込んだ場合に、前記熱可塑性樹脂製部材に当接するストッパが設けられており、前記熱可塑性樹脂製レンズは、前記保持工程において前記熱可塑性樹脂製部材に全周にわたり当接する環状接合面を先端に有する環状リブと、前記環状リブの近傍の前記熱可塑性樹脂製レンズ裏面に形成された前記熱可塑性樹脂製部材側に凸のローレット、若しくは前記環状リブの内周面と前記レンズ裏面との間に形成された駄肉部と、を含み、前記走査工程は、前記環状リブを透過して前記環状リブ側の環状接合面が当接した前記熱可塑性樹脂製部材側の環状接合面を照射し、前記熱可塑性樹脂製部材側の環状接合面とこれに当接した前記環状リブ側の環状接合面とを溶融して接合するように、前記熱可塑性樹脂製レンズ表面の外周部全周にレーザー光を走査し、前記ローレットもしくは前記駄肉部が前記ストッパとして機能し、前記ストッパの高さ寸法は、前記環状リブの高さ寸法よりも短く設定されていることを特徴とする。 In order to solve the above-mentioned problem, the invention according to claim 1 is a vehicle in which a thermoplastic resin lens that is transparent to laser light and a thermoplastic resin member that is absorbent to laser light are laser-welded. In the method for manufacturing a lamp, a holding step of holding the thermoplastic resin lens and the thermoplastic resin member in a state of being pressed and in contact with each other, and transmitting the thermal resin through the thermoplastic resin lens. Irradiating the thermoplastic resin member abutting on the outer peripheral portion of the back surface of the lens made of plastic resin, so that the thermoplastic resin member and the thermoplastic resin lens abutting on the member are melted and joined, a scanning step of scanning the laser beam on the outer periphery entire periphery of the thermoplastic resin lens surface includes a, to the thermoplastic resin lenses, the thermoplastic resin lens is the thermoplastic resin When sunk to member, the thermoplastic resin member is in contact with the stopper is provided, the thermoplastic resin lens is in contact with the entire periphery to the thermoplastic resin member in said holding step cyclic An annular rib having a joining surface at the tip, and a knurled convex on the thermoplastic resin member side formed on the back surface of the thermoplastic resin lens near the annular rib, or an inner peripheral surface of the annular rib and the lens An annular joint formed on the side of the thermoplastic resin member through which the annular rib penetrates and the annular joint surface on the annular rib side abuts. The outer peripheral portion of the surface of the lens made of thermoplastic resin so as to melt and join the annular joint surface on the thermoplastic resin member side and the annular joint surface on the annular rib side in contact with the surface. All around Scanning the Za light, the function as knurling or the paddings portion said stopper, the height of the stopper is characterized in that it is shorter than the height of the annular rib.

請求項１に記載の発明によれば、熱可塑性樹脂製レンズ又は熱可塑性樹脂製部材に当接するストッパの作用により、熱可塑性樹脂製レンズ表面の外周部全周を走査し、その全周にわたりレーザー溶着を行うことに起因する熱可塑性樹脂製レンズの熱可塑性樹脂製部材に対する沈み込み量を制御することが可能となる。   According to the first aspect of the present invention, the entire circumference of the outer surface of the thermoplastic resin lens surface is scanned by the action of a stopper that comes into contact with the thermoplastic resin lens or the thermoplastic resin member, and the laser is applied over the entire circumference. It is possible to control the amount of sinking of the thermoplastic resin lens into the thermoplastic resin member resulting from the welding.

請求項２に記載の発明は、請求項１に記載の発明において、前記熱可塑性樹脂製レンズの裏面に施されたローレットは、前記環状リブおよび前記熱可塑性樹脂製レンズの外周に沿って延びる断面半円形状であることを特徴とする。 According to a second aspect of the present invention, in the first aspect of the present invention, the knurl provided on the back surface of the thermoplastic resin lens extends along the outer circumference of the annular rib and the thermoplastic resin lens. It has a semicircular shape .

請求項２に記載の発明によれば、主に意匠目的のローレットをストッパとして機能させることが可能となるため、専用のストッパが不要となる。
請求項３に記載の発明は、請求項１に記載の発明において、前記走査工程は、前記熱可塑性樹脂製レンズの上方に固定されたガルバノスキャンヘッドにて前記レーザー光を走査していることを特徴とする請求項１に記載のレーザー溶着を用いた。 According to the second aspect of the present invention, it becomes possible to mainly function a knurling for design purposes as a stopper, so that a dedicated stopper becomes unnecessary.
The invention according to claim 3 is the invention according to claim 1, wherein the scanning step scans the laser beam with a galvano scan head fixed above the lens made of thermoplastic resin. The laser welding according to claim 1 is used.

以上説明したように、本発明によれば、熱可塑性樹脂製レンズ表面の外周部全周を走査し、その全周にわたりレーザー溶着を行うことに起因する熱可塑性樹脂製部材に対する熱可塑性樹脂製レンズの沈み込み量を制御することが可能なレーザー溶着を用いた車両用灯具製造方法を提供することが可能となる。   As described above, according to the present invention, the thermoplastic resin lens for the thermoplastic resin member caused by scanning the entire outer periphery of the surface of the thermoplastic resin lens and performing laser welding over the entire periphery. It is possible to provide a method for manufacturing a vehicular lamp using laser welding capable of controlling the amount of subsidence.

本発明の一実施形態であるレーザー溶着方法に用いられるレーザー溶着装置１０の概略構成図である。It is a schematic block diagram of the laser welding apparatus 10 used for the laser welding method which is one Embodiment of this invention. （ａ）レンズ２０とハウジング３０の断面図（沈み込み前）、（ｂ）レンズ２０とハウジング３０の断面図（沈み込み後）である。(A) Cross-sectional view of lens 20 and housing 30 (before sinking), (b) Cross-sectional view of lens 20 and housing 30 (after sinking). （ａ）レンズ２０とハウジング３０の断面図（変形例。沈み込み前）、（ｂ）レンズ２０とハウジング３０の断面図（変形例。沈み込み後）である。(A) Cross-sectional view of lens 20 and housing 30 (modified example, before sinking), (b) Cross-sectional view of lens 20 and housing 30 (modified example, after sinking). レンズ２０とハウジング３０の断面図（変形例。沈み込み前）である。FIG. 6 is a cross-sectional view of the lens 20 and the housing 30 (modified example before sinking). （ａ）レンズ２０（変形例）の上面図、（ｂ）レンズ２０とハウジング３０の断面図（変形例。沈み込み前）である。(A) Top view of lens 20 (modified example), (b) Cross-sectional view of lens 20 and housing 30 (modified example, before sinking). レンズ２０とハウジング３０の断面図（変形例。沈み込み前）である。FIG. 6 is a cross-sectional view of the lens 20 and the housing 30 (modified example before sinking). レンズ２０とハウジング３０の断面図（変形例。沈み込み前）である。FIG. 6 is a cross-sectional view of the lens 20 and the housing 30 (modified example before sinking). 従来のレーザー溶着方法に用いられるレーザー溶着装置の概略構成を説明するための図である。It is a figure for demonstrating schematic structure of the laser welding apparatus used for the conventional laser welding method. （ａ）熱可塑性樹脂製レンズ２１０と熱可塑性樹脂製部材２２０の断面図（沈み込み前）、（ｂ）熱可塑性樹脂製レンズ２１０と熱可塑性樹脂製部材２２０の断面図（沈み込み後）である。(A) Cross section of thermoplastic resin lens 210 and thermoplastic resin member 220 (before sinking), (b) Cross sectional view of thermoplastic resin lens 210 and thermoplastic resin member 220 (after sinking) is there.

以下、本発明の一実施形態であるレーザー溶着を用いた車両用灯具製造方法について、図面を参照しながら説明する。   Hereinafter, a vehicle lamp manufacturing method using laser welding according to an embodiment of the present invention will be described with reference to the drawings.

本実施形態のレーザー溶着方法に用いられるレーザー溶着装置１０は、レンズ２０とこのレンズ２０に組み合わされて車両用灯具（例えば、車両後部の左右両側にそれぞれ配置されるリアコンビネーションランプ）を構成するハウジング３０とをレーザー溶着するための装置であり、図１に示すように、レーザー光学系４０等を備えている。   A laser welding apparatus 10 used in the laser welding method of the present embodiment includes a lens 20 and a housing that constitutes a vehicle lamp (for example, a rear combination lamp disposed on each of the left and right sides of the rear portion of the vehicle) in combination with the lens 20. 30, and a laser optical system 40 as shown in FIG. 1.

レンズ２０は、レーザー光に対し透過性を有する熱可塑性樹脂製レンズである。レンズ２０は、例えば、第１レンズ部２１と、屈曲レンズ部２２を介して第１レンズ部２１に連続する第２レンズ部２３と、を含んでいる。   The lens 20 is a thermoplastic resin lens that is transparent to laser light. The lens 20 includes, for example, a first lens unit 21 and a second lens unit 23 that is continuous with the first lens unit 21 via the bent lens unit 22.

図２（ａ）に示すように、レンズ２０裏面の外周部には、先端に環状接合面２４ａを含む環状リブ２４が形成されている。   As shown in FIG. 2A, an annular rib 24 including an annular joint surface 24a at the tip is formed on the outer peripheral portion of the rear surface of the lens 20.

ハウジング３０は、レーザー光に対し吸収性を有する熱可塑性樹脂製部材である。図２（ａ）に示すように、ハウジング３０は、レンズ２０（環状リブ２４の環状接合面２４ａ）が当接する環状接合面３１を含んでいる。環状接合面３１の内周側には、ストッパＳが形成されている。ストッパＳの高さ寸法Ｈ１は、環状リブ２４の高さ寸法Ｈ２よりも短く設定されている。 The housing 30 is a thermoplastic resin member that absorbs laser light. As shown in FIG. 2A, the housing 30 includes an annular joint surface 31 with which the lens 20 (the annular joint surface 24a of the annular rib 24) abuts. A stopper S is formed on the inner peripheral side of the annular joint surface 31. The height dimension H 1 of the stopper S is set shorter than the height dimension H 2 of the annular rib 24.

レーザー光学系４０としては、例えば、レーザー溶着に用いられるレーザー光を走査するガルバノミラー等（図示せず）を含むガルバノスキャンヘッド、又は、公知のロボットアームに支持されたレーザー射出装置を用いることが可能である。なお、レーザー光学系４０がガルバノスキャンヘッドである場合には、当該ガルバノスキャンヘッドは公知のフレーム等（図示せず）に固定されて用いられる。   As the laser optical system 40, for example, a galvano scan head including a galvano mirror or the like (not shown) that scans laser light used for laser welding, or a laser emission device supported by a known robot arm is used. Is possible. When the laser optical system 40 is a galvano scan head, the galvano scan head is used by being fixed to a known frame or the like (not shown).

次に、上記構成のレーザー溶着装置１０を用いてレンズ２０とハウジング３０とをレーザー溶着する車両用灯具製造方法について説明する。   Next, a vehicle lamp manufacturing method for laser welding the lens 20 and the housing 30 using the laser welding apparatus 10 having the above configuration will be described.

まず、レンズ２０とハウジング３０とを加圧し、レンズ２０（環状接合面２４ａ）とハウジング３０（環状接合面３１）とをその全周にわたり互いに当接（密着）させた状態（図２（ａ）参照）で公知の治具（図示せず）等により保持する。   First, the lens 20 and the housing 30 are pressurized, and the lens 20 (annular joint surface 24a) and the housing 30 (annular joint surface 31) are in contact with each other over the entire circumference (FIG. 2 (a)). And a known jig (not shown) or the like.

次に、レンズ２０（環状リブ２４）を透過したレーザー光が、当該レンズ２０（環状接合面２４ａ）が当接したハウジング３０（環状接合面３１）を照射し、当該ハウジング３０（環状接合面３１）とこれに当接したレンズ２０とを溶融して接合するように、レンズ２０表面の外周部全周にレーザー光Ｒａｙを走査する（図１参照）。   Next, the laser light transmitted through the lens 20 (annular rib 24) irradiates the housing 30 (annular joint surface 31) with which the lens 20 (annular joint surface 24a) abuts, and the housing 30 (annular joint surface 31). ) And the lens 20 in contact therewith are scanned with the laser beam Ray over the entire outer periphery of the surface of the lens 20 (see FIG. 1).

レンズ２０とハウジング３０とは加圧され、レンズ２０（環状接合面２４ａ）とハウジング３０（環状接合面３１）とがその全周にわたり互いに当接（密着）した状態（図２参照（ａ）参照）で保持されているため、その全周にわたりレーザー溶着が行われると、レンズ２０がハウジング３０に対し沈み込む（図２（ｂ）参照）。   The lens 20 and the housing 30 are pressurized, and the lens 20 (annular joint surface 24a) and the housing 30 (annular joint surface 31) are in contact with each other over the entire circumference (see FIG. 2 (a)). Therefore, when laser welding is performed over the entire circumference, the lens 20 sinks into the housing 30 (see FIG. 2B).

しかし、レンズ２０がハウジング３０に対しある程度沈み込むと環状接合面３１の内周側に形成されたストッパＳ（全周にわたって連続的に又は散点的に形成されている）がレンズ２０（例えば、レンズ２０裏面のうち環状リブ２４の近傍）に当接するため（図２（ｂ）参照）、その沈み込み量を制御することが可能となる。   However, when the lens 20 sinks to some extent with respect to the housing 30, the stopper S (formed continuously or scattered over the entire periphery) formed on the inner peripheral side of the annular joint surface 31 is replaced with the lens 20 (for example, Since it abuts on the back surface of the lens 20 (in the vicinity of the annular rib 24) (see FIG. 2B), the amount of sinking can be controlled.

以上により、レンズ２０とハウジング３０とをその沈み込み量を制御しつつ、その外周部全周にわたりレーザー溶着することが可能となる。   As described above, the lens 20 and the housing 30 can be laser-welded over the entire outer periphery of the lens 20 while controlling the sinking amount.

図３（ａ）に示すように、ストッパＳは、その外側面Ｓａが環状リブ２４の内側面２４ｂに密着するようにハウジング３０側の環状接合面３１の内周側に形成されているのが好ましい（図３（ａ）、図３（ｂ）参照）。このようにすれば、ストッパＳの外側面Ｓａと環状リブ２４の内側面２４ｂとが密着し（図３（ｂ）参照）両者間に間隔Ｗ（図２（ａ）参照）が形成されないため、ストッパＳの外側面Ｓａと環状リブ２４の内側面２４ｂとの間にバリＢが発生するのを防止することが可能となる（図３（ｂ）参照）。 As shown in FIG. 3A, the stopper S is formed on the inner peripheral side of the annular joint surface 31 on the housing 30 side so that the outer side surface Sa is in close contact with the inner side surface 24 b of the annular rib 24. Is preferable (see FIGS. 3A and 3B). Thus, close contact with the inner surface 24b of the outer surface S a and the annular rib 24 of the stopper S is (see FIG. 3 (b)) for spacing therebetween W (see FIG. 2 (a)) is not formed , burr B it becomes possible to prevent the occurrence between the inner surface 24b of the outer surface S a and the annular rib 24 of the stopper S (see Figure 3 (b)).

ストッパＳは、レンズ２０側に設けてもよい（図４参照）。この場合、ストッパＳは、主に意匠目的でレンズ２０の裏面に施されたローレット２５であってもよい（図５（ａ）、図５（ｂ）参照）。このようにすれば、主に意匠目的のローレット２５をストッパＳとして機能させることが可能となるため、専用のストッパＳが不要となる。   The stopper S may be provided on the lens 20 side (see FIG. 4). In this case, the stopper S may be a knurled 25 provided on the back surface of the lens 20 mainly for design purposes (see FIGS. 5A and 5B). In this way, the knurling 25 for design purposes can be made to mainly function as the stopper S, so that the dedicated stopper S is not necessary.

また、図６に示すように、ストッパＳは、環状リブ２４の内周面２４ｂとレンズ２０裏面との間に形成された駄肉部２６であってもよい。このようにすれば、環状リブ２４に干渉するレーザー光Ｒａｙを減少させ、ハウジング３０（環状接合面３１）を照射するレーザー光Ｒａｙを増加させることが可能となる。また、駄肉部分２６をストッパＳとして機能させることが可能となるため、専用のストッパＳが不要となる。   As shown in FIG. 6, the stopper S may be a sunk portion 26 formed between the inner peripheral surface 24 b of the annular rib 24 and the rear surface of the lens 20. If it does in this way, it will become possible to reduce laser beam Ray which interferes with annular rib 24, and to increase laser beam Ray which irradiates housing 30 (annular joint surface 31). In addition, since the waste portion 26 can function as the stopper S, a dedicated stopper S is not required.

また、図７に示すように、ストッパＳは、環状リブ２４の先端部に形成された段差部２４ｃであってもよい。このようにすれば、段差部２４ｃをストッパＳとして機能させることが可能となるため、専用のストッパＳが不要となる。   Further, as shown in FIG. 7, the stopper S may be a stepped portion 24 c formed at the tip of the annular rib 24. In this way, the stepped portion 24c can function as the stopper S, so that the dedicated stopper S is not necessary.

以上説明したように、本実施形態の車両用灯具製造方法によれば、ストッパＳの作用により、レンズ２０表面の外周部全周を走査し、その全周にわたりレーザー溶着を行うことに起因するレンズ２０のハウジング３０に対する沈み込み量を制御することが可能となる。   As described above, according to the vehicle lamp manufacturing method of the present embodiment, the lens caused by scanning the entire outer periphery of the surface of the lens 20 by the action of the stopper S and performing laser welding over the entire periphery. It is possible to control the amount of sinking 20 into the housing 30.

また、本実施形態の車両用灯具製造方法によれば、レンズ２０のハウジング３０に対する沈み込み量を制御することが可能となるため、沈み込み量を制御しない場合と比べ、レンズ２０とハウジング３０との建て付け安定性を向上することが可能となる。また、レンズ２０とハウジング３０とを組み合わせて構成される灯具の配光に影響が及ぶのを防止又は低減することが可能となる。   Further, according to the vehicular lamp manufacturing method of the present embodiment, it is possible to control the sinking amount of the lens 20 with respect to the housing 30, so that the lens 20 and the housing 30 are compared with the case where the sinking amount is not controlled. It becomes possible to improve the stability of building. Further, it is possible to prevent or reduce the influence on the light distribution of the lamp configured by combining the lens 20 and the housing 30.

また、本実施形態の車両用灯具製造方法によれば、沈み込み量を制御する特別な設備を用いることなく、ストッパＳのみで沈み込み量を制御する構成であるため、設備費用を低減することが可能となる。   Moreover, according to the vehicular lamp manufacturing method of the present embodiment, since the configuration is such that the sinking amount is controlled only by the stopper S without using special equipment for controlling the sinking amount, the equipment cost can be reduced. Is possible.

次に、変形例について説明する。   Next, a modified example will be described.

上記実施形態では、熱可塑性樹脂製部材がハウジング３０の例について説明したが、本発明はこれに限定されない。例えば、熱可塑性樹脂製部材はリフレクタ等の車両用灯具構成部材、その他電子部品の小物部品等であってもよい。   In the said embodiment, although the member made from a thermoplastic resin demonstrated the example of the housing 30, this invention is not limited to this. For example, the thermoplastic resin member may be a vehicular lamp constituent member such as a reflector, or other electronic parts.

上記実施形態はあらゆる点で単なる例示にすぎない。これらの記載によって本発明は限定的に解釈されるものではない。本発明はその精神または主要な特徴から逸脱することなく他の様々な形で実施することができる。   The above embodiment is merely an example in all respects. The present invention is not construed as being limited to these descriptions. The present invention can be implemented in various other forms without departing from the spirit or main features thereof.

１０…レーザー溶着装置、２０…レンズ、２１…第１レンズ部、２２…屈曲レンズ部、２３…第２レンズ部、２４…環状リブ、２４ａ…環状接合面、２４ｂ…内周面、２４ｃ…段差部、２５…ローレット、２６…駄肉部、３０…ハウジング、３１…環状接合面、４０…レーザー光学系   DESCRIPTION OF SYMBOLS 10 ... Laser welding apparatus, 20 ... Lens, 21 ... 1st lens part, 22 ... Bending lens part, 23 ... 2nd lens part, 24 ... Annular rib, 24a ... Annular joint surface, 24b ... Inner peripheral surface, 24c ... Level difference Part, 25 ... knurling, 26 ... dumb part, 30 ... housing, 31 ... annular joint surface, 40 ... laser optical system

Claims (3)

レーザー光に対し透過性を有する熱可塑性樹脂製レンズとレーザー光に対し吸収性を有する熱可塑性樹脂製部材とがレーザー溶着された車両用灯具を製造する方法において、
前記熱可塑性樹脂製レンズと前記熱可塑性樹脂製部材とを加圧し互いに当接させた状態で保持する保持工程と、
前記熱可塑性樹脂製レンズを透過して前記熱可塑性樹脂製レンズ裏面の外周部が当接した前記熱可塑性樹脂製部材を照射し、前記熱可塑性樹脂製部材とこれに当接した前記熱可塑性樹脂製レンズとを溶融して接合するように、前記熱可塑性樹脂製レンズ表面の外周部全周にレーザー光を走査する走査工程と、
を含んでおり、
前記熱可塑性樹脂製レンズには、当該熱可塑性樹脂製レンズが前記熱可塑性樹脂製部材に対し沈み込んだ場合に、前記熱可塑性樹脂製部材に当接するストッパが設けられており、
前記熱可塑性樹脂製レンズは、前記保持工程において前記熱可塑性樹脂製部材に全周にわたり当接する環状接合面を先端に有する環状リブと、前記環状リブの近傍の前記熱可塑性樹脂製レンズ裏面に形成された前記熱可塑性樹脂製部材側に凸のローレット、若しくは前記環状リブの内周面と前記レンズ裏面との間に形成された駄肉部と、を含み、
前記走査工程は、前記環状リブを透過して前記環状リブ側の環状接合面が当接した前記熱可塑性樹脂製部材側の環状接合面を照射し、前記熱可塑性樹脂製部材側の環状接合面とこれに当接した前記環状リブ側の環状接合面とを溶融して接合するように、前記熱可塑性樹脂製レンズ表面の外周部全周にレーザー光を走査し、
前記ローレットもしくは前記駄肉部が前記ストッパとして機能し、
前記ストッパの高さ寸法は、前記環状リブの高さ寸法よりも短く設定されていることを特徴とするレーザー溶着を用いた車両用灯具製造方法。 In a method of manufacturing a vehicular lamp in which a thermoplastic resin lens that is transparent to laser light and a thermoplastic resin member that is absorbent to laser light are laser-welded,
A holding step of holding the thermoplastic resin lens and the thermoplastic resin member in a state of being pressed and brought into contact with each other;
The thermoplastic resin member that is transmitted through the thermoplastic resin lens and irradiates the thermoplastic resin member that is in contact with the outer peripheral portion of the back surface of the thermoplastic resin lens, and the thermoplastic resin member that is in contact with the thermoplastic resin member. A scanning step of scanning a laser beam around the entire outer periphery of the surface of the thermoplastic resin lens so as to melt and bond the lens
Contains
In the thermoplastic resin lens, if the thermoplastic resin lens is sunk relative to the thermoplastic resin member, and abutting a stopper is provided on the thermoplastic resin member,
The thermoplastic resin lens is formed on an annular rib having an annular joint surface at the tip that contacts the thermoplastic resin member over the entire circumference in the holding step, and on the back surface of the thermoplastic resin lens in the vicinity of the annular rib. A convex knurl on the thermoplastic resin member side, or a fillet portion formed between the inner peripheral surface of the annular rib and the lens back surface,
The scanning step irradiates an annular joint surface on the thermoplastic resin member side through which the annular rib penetrates and the annular joint surface on the annular rib side contacts, and the annular joint surface on the thermoplastic resin member side In order to melt and join the annular joint surface on the annular rib side that is in contact with this, a laser beam is scanned on the entire outer periphery of the surface of the thermoplastic resin lens,
The knurling or the meat portion functions as the stopper,
The vehicle lamp manufacturing method using laser welding , wherein a height dimension of the stopper is set shorter than a height dimension of the annular rib . 前記熱可塑性樹脂製レンズの裏面に施されたローレットは、前記環状リブおよび前記熱可塑性樹脂製レンズの外周に沿って延びる断面半円形状であることを特徴とする請求項１に記載のレーザー溶着を用いた車両用灯具製造方法。 The knurled subjected to the back surface of the front Kinetsu thermoplastic resin lens, laser according to claim 1, wherein a cross-sectional semi-circular shape extending along the outer periphery of the annular rib and the thermoplastic resin lens A vehicle lamp manufacturing method using welding. 前記走査工程は、前記熱可塑性樹脂製レンズの上方に固定されたガルバノスキャンヘッドにて前記レーザー光を走査していることを特徴とする請求項１に記載のレーザー溶着を用いた車両用灯具製造方法。2. The vehicular lamp manufacturing method according to claim 1, wherein in the scanning step, the laser beam is scanned by a galvano scan head fixed above the thermoplastic resin lens. Method.
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