JP5977013B2 - レーザー溶接構造 - Google Patents

レーザー溶接構造 Download PDF

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JP5977013B2
JP5977013B2 JP2011229638A JP2011229638A JP5977013B2 JP 5977013 B2 JP5977013 B2 JP 5977013B2 JP 2011229638 A JP2011229638 A JP 2011229638A JP 2011229638 A JP2011229638 A JP 2011229638A JP 5977013 B2 JP5977013 B2 JP 5977013B2
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resin molded
molded product
shade
laser
resin
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JP2013089483A (ja
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雄治 安田
雄治 安田
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Koito Manufacturing 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
    • 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
    • B29C65/78—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
    • B29C65/7805—Positioning the parts to be joined, e.g. aligning, indexing or centring the parts to be joined comprising positioning features
    • B29C65/7814—Positioning the parts to be joined, e.g. aligning, indexing or centring the parts to be joined comprising positioning features in the form of inter-cooperating positioning features, e.g. tenons and mortises
    • 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
    • B29C66/114—Single butt joints
    • 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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B29C66/2422—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being circular, oval or elliptical
    • B29C66/24221—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being circular, oval or elliptical being circular
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot 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
    • 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
    • B29C66/83—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
    • 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)

Description

本発明は、レーザー光を用いて２つの樹脂成形品を溶接する構造に関する。
従来、レーザー光を用いて車両用灯具のレンズとシェードを溶接する構造が知られている。例えば、図５に示す車両用灯具５１では、透明なレンズ５２の端面と不透明なシェード５３の端面とを接合し、レンズ５２のフランジ部５２aを透過したレーザー光によってシェード５３の溶着部５４を溶かし、溶着部５４の溶融樹脂でレンズ５２をシェード５３に溶接している。
また、シェード５３の端面には、レーザー光が照射されない位置に、円周方向の位置決めピン５５と光軸方向の位置決めダボ５６とが突設されている。そして、溶着部５４が溶けたときに、位置決めダボ５６をフランジ部５２aに当接させ、レンズ５２の沈み込みを防止し、レンズ５２とシェード５３を光軸方向に精度よく組み付けできるようになっている。なお、特許文献１には、位置決めダボを用いたレーザー溶接構造が記載されている。
特開２００８−２６２８７６号公報
ところが、従来のレーザー溶接構造によると、レンズ５２とシェード５３の組付精度を維持するために、シェード５３の端面に溶着部５４とは別の形状部つまり位置決めダボ５６を突設する必要があった。したがって、シェード成形用金型の加工数が増え、車両用灯具５１の製作コストが高くつくという問題点があった。
本発明の目的は、同一形状部に溶着部と位置決め部を設け、簡単な構成で２つの樹脂成形品を精度よく溶接できるレーザー溶接構造を提供することにある。
上記課題を解決するために、本発明は、第１樹脂成形品と第２樹脂成形品とを接合し、第１樹脂成形品を透過したレーザー光によって第２樹脂成形品の一部を溶融し、溶融樹脂で第１および第２樹脂成形品を溶接するレーザー溶接構造において、次のような特徴的手段を提供する。
（１）第２樹脂成形品に第１樹脂成形品が載置される載置棚を突設し、載置棚の一部にレーザー光によって溶融される溶着部を設け、載置棚の残りの部分をレーザー光によって溶融されない位置決め部としたことを特徴とするレーザー溶接構造。
（２）第１樹脂成形品がレーザー光透過性樹脂で成形されたレンズを含み、第２樹脂成形品がレーザー光吸収性樹脂で成形されたシェードを含むことを特徴とする（１）に記載のレーザー溶接構造。
（３）シェードの端面に複数の載置棚を突設し、各載置棚の位置決め部によりレンズを光軸方向に位置決めしたことを特徴とする（２）に記載のレーザー溶接構造。
（４）シェードの端面を円環状に形成し、該端面の円周方向複数位置に載置棚を突設し、各載置棚の両端に位置決め部を設定し、位置決め部の間に溶着部を設定したことを特徴とする（３）に記載のレーザー溶接構造。
（５）隣接する載置棚の間において、シェードの端面にレンズを周方向に位置決めするピンを突設したことを特徴とする（４）に記載のレーザー溶接構造。
本発明のレーザー溶接構造によれば、第２樹脂成形品の同一形状部である載置棚に溶着部と位置決め部とをレーザー光によって画定するので、成形用金型の加工数を増やすことなく、簡単な構成で２つの樹脂成形品を精度よく溶接できるという効果がある。
本発明の一実施形態を示す車両用灯具の分解斜視図である。 レンズとシェードのレーザー溶接構造を示す立面図である。 載置棚の溶着部と位置決め部を示すシェードの端面図である。 溶着部と位置決め部の作用を示す図３のＡ矢視図である。 従来の車両用灯具のレーザー溶接構造を示す斜視図である。
以下、本発明を車両用灯具に具体化した一実施形態を図面に基づいて説明する。図１に示す車両用灯具１は、第１樹脂成形品としてのレンズ２と、第２樹脂成形品としてのシェード３とを備え、シェード３の内側に光源４が収められている。
レンズ２は、レーザー光を透過する透明樹脂材料で成形され、周縁に円形のフランジ部２aが一体的に設けられている。シェード３は、レーザー光を吸収する不透明樹脂材料で成形され、内面に反射膜３ａが被着されている。
シェード３の端面はフランジ部２aと同じ大きさの円環状に形成され、端面の円周方向４箇所にレンズ２が載置される載置棚６が突設されている。隣接する載置棚６の間において、シェード３の端面には２本のピン７が突設されている。フランジ部２aにはピン７が嵌入する切欠８が形成され、ピン７と切欠８の嵌合によってレンズ２が円周方向に位置決めされる。
そして、車両用灯具１の組み付けに際しては、図２に示すように、レンズ２およびシェード３の端面を接合し、フランジ部２aを載置棚６に載せ、レンズ２側に設置されたレーザー溶接機１０からレーザー光ＬＢを照射し、フランジ部２ａを透過したレーザー光ＬＢによって載置棚６の一部を溶かし、溶融樹脂９によりレンズ２とシェード３を溶接するようになっている。
図３に示すように、４つの載置棚６には、それぞれ一つの溶着部１１と２つの位置決め部１２とが設定されている。位置決め部１２は載置棚６の両端に幅狭く設定され、溶着部１１が２つの位置決め部１２の間に幅広く設定されている。レーザー溶接機１０は、レーザー光ＬＢを溶着部１１に限定的に照射し、位置決め部１２を残して溶着部１１のみを溶かすように制御される。
これにより、車両用灯具１の組付時には、図４に示すように、単一形状部である載置棚６に溶着部１１と位置決め部１２とを同時に形成し、位置決め部１２によりレンズ２を光軸方向に位置決めした状態で、溶着部１１の溶融樹脂９でレンズ２をシェード３に溶接できる。したがって、シェード３の端面からダボを省き（図１参照）、シェード成形用金型の加工数を減らし、車両用灯具１の製作コストを削減できる。
なお、本発明は、上記実施形態に限定されるものではなく、例えば、載置棚６の個数や周方向位置を変更したり、車両用灯具以外の樹脂成形品のレーザー溶接に応用したりするなど、発明の趣旨を逸脱しない範囲で、各部の構成を適宜に変更して実施することも可能である。
１ 車両用灯具
２ レンズ
３ シェード
６ 載置棚
７ ピン
９ 溶融樹脂
１１ 溶着部
１２ 位置決め部
ＬＢ レーザー光

Claims (5)

  1. 第１樹脂成形品と第２樹脂成形品とが接合され、第１樹脂成形品を透過したレーザー光によって第２樹脂成形品の一部が溶融され、溶融樹脂で第１および第２樹脂成形品が溶接されているレーザー溶接構造において、
    前記第２樹脂成形品に第１樹脂成形品が載置される載置棚が突設され、載置棚の同一平面内に前記レーザー光によって溶融される溶着部と、前記レーザー光によって溶融されない位置決め部とが設定され、
    前記レーザー光が溶着部に限定的に照射されることによって、位置決め部により第１樹脂成形品の沈み込みが防止された状態で、溶着部の溶融樹脂により第１樹脂成形品が第２樹脂成形品に溶接されていることを特徴とするレーザー溶接構造。
  2. 前記第１樹脂成形品がレーザー光透過性樹脂で成形されたレンズを含み、前記第２樹脂成形品がレーザー光吸収性樹脂で成形されたシェードを含む請求項１記載のレーザー溶接構造。
  3. 前記シェードの端面に複数の載置棚が突設され、各載置棚の位置決め部により前記レンズが光軸方向に位置決めされている請求項２記載のレーザー溶接構造。
  4. 前記シェードの端面が円環状に形成され、該端面の円周方向複数位置に前記載置棚が突設され、各載置棚の両端に前記位置決め部が形成され、位置決め部の間に前記溶着部が設けられている請求項３記載のレーザー溶接構造。
  5. 隣接する載置棚の間において、シェードの端面にレンズを周方向に位置決めするピンが突設されている請求項４記載のレーザー溶接構造。
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