JPS60201935A - Lighting fixture lens and manufacture thereof - Google Patents

Abstract

PURPOSE:To improve lightening properties, safety and economical efficiency by laminating and unifying a thermoplastic plastic film or sheet and a resin layer, which is formed through projection molding and a opposite surface thereof has lens functional irregularities. CONSTITUTION:A thermoplastic plastic film or sheet 5, which is fitted previously to molds 7, 7' for molding a lighting fixture lens and on one surface thereof a hard coating film is formed, is fusion-bonded and unified thermally with a molten resin layer 6 flowing in through a sprue 2, a runner 3 and a gate 4. As for a film on one surface thereof a hard-coating membrane is formed, or a plastic material to be used for sheet, and thermoplastic material to be used for injection molding are normally preferable when the same kind of the material is employed with respect to fusion welding property and optical uniformity. A polycarbonate resin, etc. is employed as thermoplastic plastics.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a synthetic resin lamp lens having surface hardness on one side and lens functional unevenness on the other side, and a method for manufacturing the same, which can be used for headlamps, cornering lamps, and Zydoturn. The present invention relates to lighting lenses for automobiles such as signal lamps, front combination lamps, rear turn signal lamps, stop lamps, backup lamps, license plate lamps, fumesoglamps, etc.

Glass and acrylic resin are used for automotive lighting lamp lenses. However, inorganic glass has drawbacks such as being heavy, being breakable, being limited in shape and color, and having low productivity.

Recently, there has been a strong demand for automotive lighting equipment to be lighter, have a shape design with less air resistance, improve heat resistance through compactness, and rationalize the method of attachment to the case body. The development of lamp lenses using synthetic resins with excellent properties is strongly encouraged.

In response to the above requirements, we have improved the shortcomings of the conventional method, and
In order to meet this demand, the following methods have been used in the past.

This method uses a heat-resistant, high-strength synthetic resin such as polycarbonate resin to obtain a molded product by injection molding, and does not apply a hard coat to the surface of the molded product by a method such as a depping method, a spray method, or an ultraviolet curing method.

This method uses a highly fluid material to reduce optical distortion, but the impact strength decreases significantly during the paint curing process, and annealing is required to prevent the occurrence of cranks during the painting process. The disadvantages are that the coating process is complicated, and the cost is high.

In addition, it may be caused by thermal surface warping of the extrusion plate or casting plate, but in this case, it is difficult to form lens functional unevenness on the opposite surface, and the shape is limited and optical distortion occurs. There is a simple drawback.

The present invention provides a lamp lens made of synthetic resin and a method for manufacturing the same, which improves or overcomes the drawbacks of conventional methods.

That is, the present invention is a lamp lens formed by laminating and integrating a thermoplastic plastic film or sheet with a hard coat film applied on one side and a resin layer formed by injection molding and having lens functional unevenness on the opposite side, In a preferred embodiment, a thermoplastic film or sheet coated on one side is made of a polycarbonate resin having a molecular weight of 25,000 or more, and the lens is formed by injection molding. The resin layer having unevenness has a molecular weight of 15,000 to 25,00.
It is composed of 0 polycarbonate resin,
This lamp lens is made of (1) thermoplastic plastic coated with a hard coat film on one side.

A step of punching out a film or sheet into the same shape as the lamp lens to create a lamp lens-shaped punched piece, (2) mounting the punched piece into a part of the cavity corresponding to the lens part of the mold for molding the lamp lens. Process, (3
) the mold is closed and molten resin is injected at high pressure by an injection molding means to laminated and integrally mold the lamp lens printing part; and (4) the molded product is taken out from the mold. Further, a process of punching out a thermoplastic plastic film or sheet coated with Bartco-1 film on one side into the same shape as the lamp lens to create a lamp lens-shaped punching piece, and using the punching piece for molding the lamp lens. At the same time, the process of filling a part of the cavity corresponding to the lens part of the mold with ;
It is rationally manufactured by a method consisting of:

First, in order to facilitate understanding of the present invention, the present invention will be explained using drawings.

FIG. 1 is an example of an overall view of a moon viewing lens molded according to the present invention, and FIG. 2 is a sectional view taken along line AA' in FIG. 1. Figure 3 is an enlarged view of part B in Figure 1 and Figure 2, showing a thermoplastic film 4) or sheet 5 with a hard coat film applied on one side, and a lens function formed by injection molding of molten resin. Resin layer 6 with roughness
and is the product bar j integrated. Further, FIG. 4 is an explanatory diagram schematically showing the injection molding process according to the present invention,
A thermoplastic film or sheet 5 coated with a hard coat film on one side, which is pre-attached to a mold 7.7' for molding a lamp lens, is thermally connected to the molten resin layer 6 flowing through the sprue 2, runner 3, and gate 4. are fused and integrated.

The thermoplastic film or sheet 5 coated with Bartko IQ on one side can be easily fixed to the mold cavity using static electricity, suction force such as vacuum, or other conventionally known methods.

A thermoplastic film or sheet with a hard coat film on one side is a thermoplastic plastic film or sheet.
For example, the normal thickness of polycarbonate resin, polycarbonate resin-polybutylene terephthalate resin composition, polymethyl methacrylate (PMMA), acrylonitrile-styrene copolymer (As resin), transparent plastics such as polystyrene, is 100 to 1000μ,
Preferably, a film or sheet of 200 to 500μ is coated with a conventionally known hard coating agent such as epoxy resin, acrylic resin, amino resin, polysiloxane, etc., and then subjected to heat or ultraviolet rays. By curing by means.

Examples of thermoplastic plastics used in the injection molding of the present invention include those similar to the plastics used for forming the hard coat crotch.

Here, the plastics used for the film or sheet with a hard coat film formed on one side and the thermoplastic plastics 14 used for injection molding are usually of the same type in terms of thermal adhesion and optical uniformity. Preferably, the melt viscosity of the plastic used for the film or sheet is higher than that of the thermoplastic plastic used for injection molding, that is, it has a higher molecular weight. In the case of polycarbonate resin, a film or sheet with a hard coat film formed on one side having a molecular weight of 25,000 or more is used, and a molecular weight of 15,000 to 25,000 is used for injection molding.
It is better to use one. It is also possible to use different resins for the polymer used for these thermoplastic plastics, films, or sheets and the polymer for injection molding. For the purpose of promoting adhesion and preventing the film from melting and losing its shape due to the injection molding resin, a primer coat (e.g., the same as the molding resin) or a heat-fusible material similar to that of the molding resin is used. It is best to apply a curable paint, such as a heat-curing or ultraviolet curable paint, which has a higher molecular weight material as its main component, to the opposite side of the hard coating or anti-fog coating.

Furthermore, it is also possible to add dyes and pigments, ultraviolet absorbers, etc. to single-sided hard-coated plastic films or sheets or plastics for injection molding.

According to the present invention as described above, it is possible to provide lamp lenses that are lightweight, safe, and economical. Furthermore, the lamp lens of the present invention and its manufacturing method are excellent in (1) surface hardness, heat resistance, weather resistance) and adhesion of hard coat IIQ, and fully satisfy the performance as a lamp lens.

■ Under certain favorable conditions, the thermoplastic film or sheet coated with Bartco-1 film on one side is heat-sealed and integrated with the molten thermoplastic resin layer in the injection mold, so a special painting process is required. Desired surface hardness (1% resistance,
It is possible to obtain a lamp lens with no dispersion in product quality.

■Compared to conventional dipping and spray painting, there are advantages such as no need for masking, no need for annealing, and no need for painting equipment, simplifying the process and improving productivity. Moreover, costs can be reduced.

■Since there is no post-processing painting process, the defective rate can be reduced.

■By using a highly fluid material with a low molecular weight as the material for the resin layer to be injection molded, a molded product with low optical strain and residual strain can be obtained, and the high impact strength of the polycarbonate film can be maintained.1.1 It ends.

It has such characteristics.

This will be explained below using examples.

Example-1 Extruded polycarbonate film with a molecular weight of 30,000 and a thickness of 200μ (500*m x 600m)
An acrylic primer was applied to one side of the substrate by the Y-1/-Harney H-1 method and dried. Next, a silicon-based top coat was applied onto the primer by a wire barcode method and cured at 130°C for 1 hour.

Hiki I-Wish Q input table! j + - i - Omaro - Plan 1'' Knee 43L
Tadashi-1-ire (Jirihai) [In the above (Ushita Bartko-1-
119 was cut out into the shape of the lamp lens shown in FIG. 1, and mounted on a lamp lens mold having the shape shown in FIG. Next, polycarbonate 1 with a molecular weight of 23,000
- The resin was injection molded. (Lighting lens 131,
The Bar 1 coated film-forming film and the molded resin material were completely integrated, and no boundary line was discernible. Damage to hard coat film, appearance gray 7; no stains observed]・1°.

Additionally, Table 1 shows the results of a performance evaluation test of the obtained lamp lens. From this table, it is clear that the performance is better than fE.

Note) *j: 80°C, 2 hours - 1 hour, cooled to -20°C, m - 20°C, 2 hours, one cycle after 50 cycles.

*2: Carbon arc sunshine weather meter test *3: Base grain peeling test

[Brief explanation of the drawing]

FIG. 1 is a perspective view for explaining the lamp lens of the present invention;
Figure 2 is a sectional view taken along line AA' in Figure 1, Figure 3 is B in Figure 2.
FIG. 4 is a partially enlarged view schematically showing the state of injection molding of the lamp lens of the present invention. The numbers in the figure are as follows: 1: lamp lens 2: varnish blue r (= runner) 4: gate 5: l surface hard coat film 6: resin layer formed by injection molding 7.7°; no mold is shown. #1 Diagram / Sin A4 Diagram

Claims (1)

[Scope of Claims] 1. A lamp lens 2 formed by laminating and integrating a thermoplastic plastic film or sheet with a hard coat film applied on one side and a resin layer formed by injection molding and having lens functional unevenness on the opposite side. , a thermoplastic plastic film or sheet coated on one side with a Bartco-1 film is made of a polycarbonate resin with a molecular weight of 25,000 or more, and a resin layer having lens functional irregularities formed by injection molding is formed with a molecular weight of 15, 3. A synthetic resin lamp lens according to claim 1, which is made of polycarbonate resin having a molecular weight of 000 to 25,000. (Step 11 of punching out a thermoplastic plastic film or sheet coated with a hard coat film on one side to the same shape as the lamp lens to create a lamp lens-shaped punched piece; (2) using the punched piece for molding a lamp lens; (3) closing the mold and injecting molten resin at high pressure using an injection molding means to integrally mold the lamp lens layer part; (4) ) Step 4 of manufacturing a synthetic resin lamp lens having a desired surface hardness, which includes the step of taking out the molded product from the mold, and forming a thermoplastic plastic film or sheet with a hard coat film on one side in the same shape as the lamp lens. The mold closes the mold. Claim 4 consisting of simultaneous operations in a process
Manufacturing method of synthetic BFI lamp lens described in section 1.