JPH0480824B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a reflector for a resin floodlight, and more particularly to a reflector for a headlamp used in an automobile.

Headlights are important for cars to drive safely at night. Figure 1 shows an overview of the car. In FIG. 1, 1 is a headlamp.

There are various kinds of such headlamps, but the ones shown in Figure 2~
Figure 4 shows a few examples. The headlamp shown in FIG. 2 is called an assembled headlamp, and as shown exploded in the figure, the headlamp is constructed by assembling a lens 2, a reflector 3, and a lamp bulb (light bulb) 4. In addition, in FIG. 2, 5 is a patch.

The headlamp shown in FIG. 3 is called a semi-shielded beam headlamp, in which a lens 6 and a reflector 7 are fixed together, and only the lamp bulb 8 can be pulled out to the rear. Furthermore, the third
In the figure, 9A is a packing, and 9B is a settling. Next, the headlamp shown in FIG. 4 is called a sealed beam headlamp in which the headlamp itself is a lamp bulb. Gas is sealed.

In such a headlamp, the reflector serves as a housing for storing the lamp bulb, etc., and generally serves as a surface mirror (reflector), and the inner surface of the reflector is coated with aluminum or the like, for example, As shown in Figure 4, beam 1
3, the area in front of the vehicle is illuminated.

Conventionally, such reflectors are made of resin,
It is also known to provide a reflector with a sanderch structure made of the resin. However, the conventional example has the following problems.

(1) As mentioned above, the inner surface of the reflector needs to reflect the light emitted from the light source and illuminate the front. Therefore, it is generally necessary to perform metallization such as the above-mentioned aluminum vapor deposition, and for this purpose, a resin molded body having a very smooth curved surface is essential. However, in conventional examples, it has been difficult to obtain such resin molded bodies.

(2) Furthermore, the inner surface of the reflector lamp housing, especially the upper inner surface, is exposed to high temperatures due to the heat from the light source and is therefore susceptible to deformation. It may be thought that it would be better to have a thicker wall, but on the contrary, heat conduction is suppressed. Therefore, it was difficult to solve the problem.

(3) Furthermore, the adhesion between the middle layer (core layer) and the front and back layers (skin layer) of the resin reflector lamp housing itself, which has a three-layer structure, is not always sufficient and may peel and deform under long-term use conditions. The drawback was that sufficient lighting effects could not be obtained.

The present inventors have completed the present invention as a result of various studies aimed at improving the drawbacks of conventional products.

That is, the present invention is characterized in that the intermediate layer is made of a polyamide resin containing glass fiber and/or a filler, and the front and back layers are made of a resin molded article with a sandwich structure made of polyamide resin. The present invention relates to a reflector for a resin floodlight.

The polyamide resin used in the present invention refers to polyamides such as nylon 6.6 and nylon 6, which are used as a general term for polymers having acid amide bonds,
Nylon copolymer refers to copolymers formed by polymerizing with other monomers in a range of 20% or less, and blends with other polymers such as polyethylene, polypropylene, polycarbonate, polybutylene terephthalate, polysulfone, etc. .

Although various types of polyamide resins can be used as mentioned above, nylon 6.6 and nylon 6 are preferable, and among them, nylon 6.6 has been found to be most suitable for the desired purpose of the present invention. The present invention will be explained below using nylon 6.6. ].

The reflector of the present invention uses nylon 6.6 for its front and back layers (hereinafter referred to as skin layers), and uses nylon 6.6 for its center layer (hereinafter referred to as core layer).
In this case, compositions with added glass fibers and/or fillers are used.

The filler is preferably talc, clay, kaolin, wollastonite, mica, or the like.

The mixing ratio of glass fiber and filler to nylon 6/6 is 5 to 65 wt%, preferably 10 to 60 wt%.
It is.

Since the reflector according to the present invention contains glass fibers and fillers in the resin constituting the core layer, it has excellent rigidity, strength, and heat deformation resistance, and the skin layer does not have such reinforcement. Because the material used is nylon 6.6, an extremely smooth surface can be obtained, and when the smooth surface is metallized by wet plating, vacuum deposition, sputtering, ion plating, etc., the inner surface of the housing can create lighting effects, etc. It is possible to form an excellent mirror surface.

The non-reinforced nylon 6/6 may contain up to 5% glass fiber or the above-mentioned reinforcing filler as long as it does not inhibit the formation of a smooth surface on the inner surface of the housing and does not inhibit the formation of a reflective mirror surface. Agents may also be added.

In addition, because nylon 6.6 has an extremely low melt viscosity during molding, the core layer and skin layer that make up the three-layer structure have a uniform layer structure up to the part away from the gate. The adhesion between the skin layer and the skin layer is much easier than with other resins other than polyamide resins, and deformation due to peeling of both layers can be prevented even during long-term irradiation use.

Furthermore, regarding heat resistance due to heat from the light source,
The high heat resistance of the core layer of nylon 6.6 containing glass fiber and/or reinforcing filler can prevent its thermal deformation.

Sandwich molding in the reflector of the present invention may be carried out by a conventional method generally used in this field, but it is preferably carried out by the following injection molding method.

For example, using an injection molding machine with two nozzles, first, as shown in FIG. The core layer is injected into the space 17 from a nozzle (not shown) in the direction of the arrow, and then, as shown in FIG. 6, the core layer is injected into the space from another nozzle (not shown) in the direction of the arrow. Reinforced nylon 6.6 1
Shoot 8.

Through such injection molding, the unreinforced nylon 6.6 14 injected into the space 17 is then replaced with the reinforced nylon 6.6 injected into the space 17.
6 is pressed against the mold core 15 and cavity 16 surface, and the reinforced nylon 6.6 is pressed against the core layer 1.
8, a resin molded body having a sandwich structure having a skin layer (front and back layer) 14 of non-reinforced nylon 6/6 is obtained.

In the present invention, since nylon 6.6 was used,
The melt viscosity at the time of molding is low, and as shown in FIG. In addition, since the core layer forming resin 18 is molded while pressing the skin layer forming resin 14 against the mold surface, a resin molded body (reflector) having a sanderch structure with good adhesiveness can be obtained.

Incidentally, in the above, even if non-reinforced nylon 6.6 is injected after reinforcing nylon 6.6, a resin molded body having a sandwich structure can be similarly obtained.

The conditions for injection molding in the above can be determined by taking into consideration both the surface texture of the skin layer and the fact that the core layer can be formed uniformly.

The reflector of the present invention having a sanderch structure made of reinforced nylon 6.6 and non-reinforced nylon 6.6 can of course be applied to embodiments having curved surfaces as shown in FIGS. 2 to 4, but the following Next, a reflector of a preferred embodiment devised by the present inventors will be explained with reference to FIGS. 7 and 8.

Figure 7 shows a headlamp with a rectangular reflector lamp housing, and Figure 8 shows a headlamp with a square reflector lamp housing.
A line cross-sectional view is shown.

In FIGS. 7 and 8, 19 is a glass (lens) attached to the front surface of the reflector, 20 is a reflector (housing), and the housing 20 includes a curved part 21, an upper part 22, and a lower part 23. Become. Further, 24 is a light bulb mounting portion, 25 is a skin layer (inner surface of the housing), 26 is a core layer, and 27 is a skin layer (outer surface of the housing).

In the case of such a rectangular housing, the inner surface of the housing 20, particularly the upper surface 22, is exposed to high temperatures due to heat from a light source (not shown) and is easily deformed.

In the present invention, since reinforced nylon 6.6 containing glass fiber is used for the core layer 26, it has excellent heat resistance and can sufficiently prevent thermal deformation. It has been found that in order to achieve this, it is good to configure the upper surface portion 22 with a thick portion 28 and a thin portion 29.

In FIG. 7, the ceiling wall of the housing is formed to be thin, and four ribs 28 are formed on the thin part (ceiling wall) 29 as a thick part 28 to connect the glass (lens) 19 and the housing 20. An example is shown in which it is disposed from the joint part to the edge of the curved surface part 21. Thereby, the ribs 28 prevent the ceiling wall 29 from deforming due to heat, and the ceiling wall 29 can be made thinner, so that heat conduction is also good.

According to the present invention, in addition to the above-mentioned advantages,
It is lightweight, has excellent rust prevention properties, and has high productivity as it is easy to mold.

Although the present invention has been explained above with reference to the embodiments shown in the drawings, it is not limited thereto and can be modified as appropriate.For example, in the above, the head lamp of a car was mainly explained, but it can also be used for a light of a car. It is also applied to housings such as lamp covers and lamp bodies of various lamps such as license lamps and tail lamps, and the reflector in the present invention refers to various housings (such as covers and lamp bodies) that house light sources of light irradiation devices. It can be applied not only to automobiles but also to various floodlights.

[Brief explanation of the drawing]

Fig. 1 is a perspective view of an automobile body, Fig. 2 is an exploded view of an example of an assembled type headlamp, Fig. 3 is an exploded view of an example of a semi-shielded beam headlamp, Fig. 4 is a configuration diagram of an example of a sealed beam headlamp, and Fig. 5 is an exploded view of an example of a semi-shielded beam headlamp. The figure is a cross-sectional view of an example of a mold for explaining the injection molding method in the present invention, FIG. 6 is a cross-sectional view of an example of the same mold, and FIG.
The figure is a perspective view showing an embodiment of the present invention, and FIG.
It is a figure-line sectional view. 3...Reflector, 7...Reflector, 11...
...Reflector, 14... Polyamide resin forming front and back layers (nylon 6/6), 18... Glass fiber forming intermediate layer, polyamide resin containing filler (nylon 6/6), 20... Reflector, 25... Skin layer (surface layer), 26...middle layer (core layer), 2
7...Skin layer (back layer).

Claims (1)

[Claims] 1. For a resin floodlight, characterized in that the intermediate layer is made of a polyamide resin containing glass fiber and/or a filler, and the front and back layers are made of a sanderch structure resin molded body made of polyamide resin. reflector.