JPH1196805A - Reflecting component of headlight and the like - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable use of low cost thermoplastic resin by using in-mold transcription working in the case of the formation of a light-reflecting member superior in image clarity (a mirror finished surface property) or a light design member which is superior in design performance (sense of brilliance). SOLUTION: The reflecting component of a headlamp or the like is formed by in-mold transcription processing one part or the whole face of the reflection face of the thermoplastic-made extension and reflector of the head lamp or the like comprising a lens, the extension, the reflector, and a body using transcription foil 2 having an aluminum deposition layer or the like.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reflection component such as a headlamp, in which a reflection surface of a light reflection member made of a thermoplastic resin such as a reflector and an extension is formed by in-mold molding using a transfer foil. .

[0002]

2. Description of the Related Art A reflector, which is a light reflecting component mounted on a vehicle, is a light reflecting component that efficiently reflects light emitted from a light source. For example, a reflector for an automobile headlamp is required to have extremely excellent image clarity and reflectivity in order to illuminate the front of a traveling road at night. As a raw material resin used for such a reflector, for example, a sheet molding compound (SMC) composed of an unsaturated polyester resin containing a filler is used.
Or bulk molding compound (BM
C).

Usually, a reflector is manufactured by forming a SMC or a BMC to obtain a reflector member, and then forming a metal thin film on the surface of the reflector member. Note that the reflector member and the reflector are both molded articles, but in order to distinguish them, the light reflecting member before the metal thin film is formed on the surface is called a reflector member, and the metal thin film is formed on the surface of the reflector member. The light-reflecting component after the above is sometimes called a reflector.

[0004]

These SMCs or BMCs generate a large amount of gas during molding, so that the surface of the reflector member is likely to have irregularities. Therefore, work to fill the surface of the reflector member with putty in post-processing,
Excellent appearance characteristics are given to the reflector member. In addition, since SMC and BMC are thermosetting resins, the molding cycle is long and the mass productivity is poor, and furthermore, burrs are generated at the time of molding.
This has led to higher costs. Moreover, the molding equipment
It is very expensive, about 10 times that of an injection molding device.

In the case of decorative parts such as extensions, a light reflecting thin film is formed on at least a part of the surface of a resin molded part using a thermoplastic resin. Examples of the material forming the light reflecting thin film include metals such as chromium, nickel, and aluminum, and metal compounds and alloys thereof. Examples of the film formation method include various vacuum evaporation methods such as a flash evaporation method, a sputtering method, and an ion plating method. However, these are considerably limited in product size, and are also secondary processing, resulting in poor productivity and increased costs.

[0006]

The present invention uses an in-mold transfer process when forming a light reflecting member having excellent image clarity (specularity) or a light design member having excellent design (brightness). This allows the use of inexpensive thermoplastic resins. In addition, the state of the mold surface of the cavity can be faithfully transferred to the surface of the light reflecting member, and the light reflecting member having excellent image clarity (mirror surface property) and the light design member having excellent design (brightness). The purpose is to provide.

That is, the reflecting part such as a headlamp of the present invention is a part of a reflecting surface such as an extension or a reflector formed of a thermoplastic resin such as a headlamp including a lens, an extension, a reflector, and a body. Alternatively, the entire surface is formed by in-mold transfer processing using a transfer foil 2 including a base film 2a, a release layer 2b, a front anchor layer 2c, an aluminum deposition layer 2d, a rear anchor 2e, a heat absorbing layer 2f, and an adhesive layer 2g. It is characterized by having done.

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS As shown in FIG. 2, a light reflecting member made of a thermoplastic resin according to the present invention has a resin layer 1 of extension.
The transfer foil 2 is formed by in-mold molding on the surface of a. Although not shown, a thermoplastic resin is filled in the cavity, and the transfer foil is formed by following the mold cavity.

As the thermoplastic resin forming the resin layer 1a of the light reflecting member of the present invention, olefin resins such as polyethylene resin and polypropylene resin; polystyrene resin;
Styrene resins such as AS resin, ABS resin, AES resin; methacrylic resin; polycarbonate resin; polyoxymethylene (polyacetal) resin;
Polyamide resins such as polyamide 66 and polyamide MXD6; modified polyphenylene ether (PPE) resins; polyphenylene sulfide resins; polyester resins such as polyethylene terephthalate (PET) resins and polybutylene ethylene terephthalate (PBT) resins; thermoplastics such as liquid crystal polymers Resin, or a polymer alloy resin composition comprising at least two or more resins of these thermoplastic resins can be mentioned, among which ABS resin, polyamide resin, polycarbonate resin, modified polyphenylene ether resin, polyester resin And a thermoplastic resin selected from the group consisting of a polymer alloy resin composition of polycarbonate resin / polyester resin. Stabilizers, ultraviolet absorbers, release agents, dyes and pigments may be added to the thermoplastic resin.

[0010] Further, a transfer foil is integrated by in-mold molding on a part or the entire surface of the reflecting surface of the light reflecting component as required. The transfer foil includes a base film 2a, a release layer 2b, a front anchor layer 2b.
c, aluminum deposition layer 2d, rear anchor 2e, heat absorption layer 2
f, an adhesive layer 2g, and the heat absorbing layer 2f is preferably a metallic pigment based heat absorbing layer in consideration of elongation during in-mold molding of the transfer foil.

The transfer foil formed by in-mold molding on the reflection surface of the light reflection component can improve the reflectivity by peeling the base film 2a as required.

A lamp can be cited as an example of the thermoplastic resin light reflecting component thus obtained. More specifically, a lamp reflector, a lamp extension optical system lamp, a reflector incorporated in a turn lamp, a search light, a rotating light, an emergency light, or the like can be exemplified.

Further, since a thermoplastic resin is used as a material of the light reflecting component, the fluidity of the molten resin is good, so that the injection pressure of the molten resin can be set low and the stress remaining on the light reflecting member can be reduced. As a result, the quality of the light reflecting component is improved. Further, as described above, since the injection pressure of the molten resin can be reduced, the thickness of the mold can be reduced, the molding apparatus can be reduced in size, and the manufacturing cost of the thermoplastic resin light reflecting component can be reduced. In addition, it is possible to reduce the thickness of the light reflecting member, which cannot be achieved by the conventional technique. Further, since the method is more excellent in mass productivity than the conventional method of manufacturing a light reflecting component made of glass, and can be integrated even by assembling, it is possible to reduce the number of components and reduce the manufacturing cost of the light reflecting component. .

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described based on embodiments with reference to the drawings. However, the present invention is not limited to these examples. The light reflecting portion was formed into a film by an in-mold transfer method to produce an extension which is a light reflecting component made of a thermoplastic resin. The molding cycle of the light reflecting member made of a thermoplastic resin was about 40 seconds / piece, and the mass productivity was considerably excellent. As a result of providing the heat absorbing layer 2f on the transfer foil on the formed reflector member, the pre-heating is performed before forming, the transfer foil is softened, the transfer foil is clamped on the mold surface, and the transfer is sufficiently performed when vacuuming is performed. The foil followed the mold surface, and the reflector member was formed by the in-mold transfer method. The cycle was about 40 seconds / piece, and the mass productivity was excellent.

[0015]

According to the method for molding a light reflecting member made of a thermoplastic resin of the present invention, a light reflecting member made of a thermoplastic resin having extremely excellent image clarity (mirror surface property) can be formed by in-mold transfer. is there. Even when molding is performed using a thermoplastic resin having high rigidity, low linear expansion coefficient, and high heat resistance, the transfer foil has a high elastic modulus due to the provision of the heat absorbing layer f, and is extremely excellent. It is possible to mold a light reflecting member made of a thermoplastic resin having high image clarity (specularity). The thermoplastic resin can be used in the field of molding a light reflecting member or a light reflecting component. In addition, since clear coating is not required, molding of the thermoplastic resin light reflecting member can be performed without deteriorating excellent image clarity (specularity).

Also, compared with the conventional molding method using a thermosetting resin such as SMC or BMC, a deburring step after resin molding, a putty filling step for surface finishing, a film forming step of a metal thin film, and the like are unnecessary. Therefore, not only can a large cost reduction be expected, but also a reduction in the defect rate of the light reflecting component, and homogenization and high quality of the light reflecting component can be achieved.

Further, since the flowability of the molten resin is improved, the injection pressure of the molten resin can be set low, so that the stress remaining in the thermoplastic resin light reflecting member can be reduced, and the light reflecting component of the thermoplastic resin can be reduced. Quality is improved. Further, since the injection pressure of the molten resin can be reduced, the thickness of the mold can be reduced, the size of the molding device can be reduced, and the manufacturing cost of the light reflecting member or the light reflecting component can be reduced.

[Brief description of the drawings]

FIG. 1 is a plan view showing an embodiment of the present invention.

FIG. 2 is a vertical side view showing one embodiment of the present invention.

FIG. 3 is an enlarged vertical sectional side view of a transfer foil.

FIG. 4 is a configuration diagram of a headlamp.

[Explanation of symbols]

1 extension, 1a resin layer, 2
Transfer foil, 2a base film, 2b release layer,
2c front anchor layer, 2d deposition layer, 2e rear anchor layer, 2
f heat absorption layer, 2 g adhesive layer, 3 lens, 4
Reflector, 5 body.

Claims (1)

[Claims] 1. An extension 1, which is formed of the thermoplastic resin, such as a headlamp or the like constituted by a lens 3, an extension 1, a reflector 4, and a body 5.
A transfer foil 2 composed of a base film 2a, a release layer 2b, a front anchor layer 2c, an aluminum deposition layer 2d, a rear anchor 2e, a heat absorption layer 2f, and an adhesive layer 2g is used for a part or the entire reflection surface of the reflector 4 or the like. A reflective component such as a headlamp, which is formed by in-mold transfer processing.