WO2022181173A1 - Lamp fixture for vehicle and method for manufacturing lamp fixture for vehicle - Google Patents

Lamp fixture for vehicle and method for manufacturing lamp fixture for vehicle Download PDF

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Publication number
WO2022181173A1
WO2022181173A1 PCT/JP2022/003041 JP2022003041W WO2022181173A1 WO 2022181173 A1 WO2022181173 A1 WO 2022181173A1 JP 2022003041 W JP2022003041 W JP 2022003041W WO 2022181173 A1 WO2022181173 A1 WO 2022181173A1
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WO
WIPO (PCT)
Prior art keywords
welding
cover
lamp housing
melted
vehicle
Prior art date
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PCT/JP2022/003041
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French (fr)
Japanese (ja)
Inventor
昌彦 西崎
Original Assignee
株式会社小糸製作所
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by 株式会社小糸製作所 filed Critical 株式会社小糸製作所
Priority to CN202280013347.2A priority Critical patent/CN116917111A/en
Priority to JP2023502190A priority patent/JPWO2022181173A1/ja
Publication of WO2022181173A1 publication Critical patent/WO2022181173A1/en

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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
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/29—Attachment thereof
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S45/00—Arrangements within vehicle lighting devices specially adapted for vehicle exteriors, for purposes other than emission or distribution of light

Definitions

  • the present invention relates to a technical field of a vehicle lamp in which a lamp housing and a cover are joined by welding and a method for manufacturing the vehicle lamp.
  • a vehicle lamp generally has a lamp housing having an opening and a cover that closes the opening. Each part is arranged.
  • the hot plate welding method has the advantages of ensuring high welding strength, not requiring consumables such as adhesives, and having a wide range of resins to choose from, making it suitable for joining three-dimensional products.
  • the lamp housing When the lamp housing and the cover are joined by hot plate welding, the lamp housing is provided with a welding joint portion, and the cover is provided with a welding leg portion projecting from the outer peripheral portion of the design surface portion.
  • the design surface portion is a portion whose outer surface faces the outside of the vehicle, and the welding leg portion is a portion that is joined to the welding joint portion by hot plate welding.
  • the lamp housing and cover are held by a first jig and a second jig, respectively, and the welding joints and welding legs are heated by heating the lamp housing side.
  • the hot plate is melted by the plate and the hot plate on the cover side, both hot plates are withdrawn from the lamp housing and the cover, and the second jig is moved toward the first jig.
  • the second jig is moved toward the first jig.
  • AS acrylonitrile styrene
  • a fluororesin coating is formed on the contact portion of the hot plate with the joint for welding, and release treatment is applied.
  • the mold release process using coating deteriorates due to the heat and pressure in the repeated melting process, so the coating needs to be re-formed after a certain period of time, which increases the manufacturing cost of the vehicle lamp. turn into.
  • the coating is re-formed every certain period of time, the melting operation cannot be performed during the re-forming, and the operating rate of the hot plate decreases. In some cases, they are prepared in advance, but in this case, a plurality of hot plates are required, which also increases the manufacturing cost of the vehicle lamp.
  • a method of joining the lamp housing and cover by irradiating laser light there is also a method of joining the lamp housing and cover by irradiating laser light.
  • a laser beam is transmitted through the cover while the welding leg and the welding joint are in contact with each other, and the welding joint of the lamp housing is irradiated with the laser beam.
  • the heat of the laser beam reaching the welding joint is conducted from the welding joint to the welding leg to melt the welding leg, thereby welding the welding joint and the welding leg.
  • the object of the vehicle lamp and the method for manufacturing the vehicle lamp of the present invention is to ensure a stable joint state between the lamp housing and the cover without increasing the manufacturing cost.
  • a vehicle lamp according to the present invention is a vehicle lamp including a lamp housing having an internal space and a cover covering the internal space, wherein the cover and the lamp housing are joined by welding, the cover
  • the lamp housing is provided with a design surface part whose outer surface faces the outside of the vehicle and a welding leg part projecting from the design surface part, and the lamp housing is provided with a welding joint part that is joined to the welding leg part, and heats the lamp housing.
  • the welding leg portion melted by heating the plate and the welding joint portion melted by laser beam irradiation are joined together.
  • the welding joints are not melted by the hot plate, and the welding joints and the welding legs are individually melted without being in contact with each other.
  • the lamp housing is provided with a main body portion having the internal space and a flange portion projecting outward from the outer peripheral portion of the main body portion. It is preferable that a welding protrusion projecting from the flange portion is provided as the welding joint.
  • the flange is not melted by the laser beam, so the thickness of the flange is not reduced.
  • the width of the welding protrusion be larger than the width of the welding leg.
  • the burr is less likely to protrude outward from the welding protrusion in the width direction when the welding protrusion and the welding leg are welded together.
  • the welding leg portion be heated in a non-contact state with the hot plate.
  • the welding leg is melted without the hot plate coming into contact with the welding leg, so that when the hot plate separates from the welding leg, part of the melted welding leg adheres to the hot plate. So-called stringiness does not occur.
  • a method for manufacturing a vehicle lamp according to the present invention is a method for manufacturing a vehicle lamp in which a lamp housing having an internal space and a cover covering the internal space are joined by welding, wherein the cover has an outer surface is melted by the heating of the hot plate, and the welding joint portion of the lamp housing is melted by the irradiation of the laser beam, and the lamp housing and the cover are melted. At least one of the legs is moved toward the other to join the welding leg and the welding joint.
  • the welding joints are not melted by the hot plate, and the welding joints and the welding legs are individually melted without being in contact with each other.
  • the welding joints are not melted by the hot plate and the welding joints and the welding legs are individually melted without being in contact with each other. It is not necessary to prepare a heat plate or a spare hot plate, and there is no gap between the welding joint and the welding leg, so that the lamp housing and the cover can be stably joined without increasing the manufacturing cost. can be secured.
  • FIG. 2 to FIG. 7 show an embodiment of a vehicle lamp and a method for manufacturing a vehicle lamp according to the present invention, and this figure is a cross-sectional view showing the vehicle lamp.
  • FIG. 4 is a cross-sectional view showing a portion joined by welding
  • FIG. 5 is a cross-sectional view showing a state in which the welding unit is moved between the lamp housing held by the first jig and the cover held by the second jig
  • FIG. 4 is a cross-sectional view, continued from FIG. 3, showing a state in which the welding leg portion of the cover is heated by the hot plate and the welding protrusion of the lamp housing is irradiated with laser light
  • FIG. 5 is a cross-sectional view, continued from FIG.
  • FIG. 4 showing a state in which the welding unit is retracted and the lamp housing and the cover are joined together;
  • FIG. 4 is a cross-sectional view showing a state in which a welding protrusion and a welding leg are joined;
  • FIG. 4 is a cross-sectional view showing an inclination angle and the like of an outer peripheral portion of a cover;
  • a vehicle lamp 1 has a lamp housing 2 and a cover 3, and the cover 3 is joined to the lamp housing 2 by welding.
  • the front, back, top, bottom, left, and right directions correspond to the positions at which the lamp housing 2 and the cover 3 are held when joined by welding.
  • the side on which the cover 3 is positioned is defined as the upper side
  • the side where the lamp housing 2 is positioned is defined as the lower side
  • the direction in which the outer peripheral portion of the cover 3 is positioned in the cross-sectional shape shown in each drawing is defined as the horizontal direction for convenience.
  • the vehicle lamp 1 is shown in a simple rotationally symmetrical shape in order to facilitate understanding of the present invention.
  • the lamp housing 2 and the cover 3 are joined by welding, and the respective predetermined portions of the lamp housing 2 and the cover 3 are welded and then crimped together (see FIG. 1). 1).
  • the lamp housing 2 is made of, for example, a resin material such as ABS resin or AS resin.
  • the lamp housing 2 comprises a concave body portion 4 which is open upward, an annular flange portion 5 projecting outward from the upper end portion of the body portion 4, and an annular welding protrusion projecting upward from the flange portion 5. 6.
  • the space inside the body portion 4 is formed as an internal space 4a.
  • the welding projection 6 is provided as a welding joint 10 to be joined to the cover 3, and the tip surface thereof is formed as the housing-side joint surface 6a.
  • the projection amount T of the welding projection 6 from the flange portion 5 is small, for example, 0.5 mm or more and 2 mm or less, and the welding projection 6 has a width H1 of, for example, 2 mm or more and 4 mm or less.
  • the cover 3 is formed of, for example, a resin material such as transparent acrylic, and has a design surface portion 7 whose outer surface faces the outside of the vehicle and welding leg portions 8 protruding from a portion of the interior surface 7a of the design surface portion 7 near the outer periphery. It is integrally formed.
  • the cover 3 is joined to the lamp housing 2 so as to cover the internal space 4a.
  • the design surface portion 7 is curved so as to protrude on the opposite side of the lamp housing 2 according to the shape of the vehicle body, and is formed into a curved surface.
  • the tip surface of the welding leg portion 8 is formed as a cover-side joint surface 8a.
  • the welding leg portion 8 has a projection amount slightly larger than the projection amount T of the welding protrusion 6 from the design surface portion 7, and has a width H2 of, for example, 1.5 mm or more and 4 mm or less. Therefore, the width H1 of the welding projection 6 is made larger than the width H2 of the welding leg 8. As shown in FIG.
  • the welding unit 30 has, for example, a flat base 40 , a hot plate 50 arranged on the upper surface of the base 40 , and a laser irradiation device 60 arranged on the lower surface of the base 40 .
  • the hot plate 50 has a hot plate main body 51 attached to the base 40 and an annular heat transfer protrusion 52 protruding upward from the hot plate main body 51 .
  • a tip surface of the heat transfer protrusion 52 is formed as a heat transfer surface 52a.
  • a laser beam is emitted from the laser irradiation device 60 toward the housing-side joint surface 6 a formed on the welding protrusion 6 of the lamp housing 2 .
  • the laser irradiation device 60 may be a plotter-type so-called XY laser irradiation device in which the laser head moves to a position corresponding to the irradiation position to irradiate the laser light.
  • a so-called galvano laser irradiation device that irradiates a laser beam toward a position may be used.
  • the lamp housing 2 and the cover 3 are joined by welding, the lamp housing 2 and the cover 3 are held by the first jig 70 and the second jig 80, respectively, and the cover 3 is positioned above the lamp housing 2 with a space therebetween. be done.
  • the welding unit 30 is moved between the lamp housing 2 and the cover 3 (see FIG. 3). reference).
  • the second jig 80 is moved downward so that the cover-side joint surfaces 8a formed on the welding legs 8 of the cover 3 are heated. It abuts against the heat transfer surface 52a formed on the heat transfer protrusion 52 of the plate 50 (see FIG. 4).
  • the cover-side joint surface 8a is brought into contact with the heat transfer surface 52a, the welding leg portion 8 is heated by the hot plate 50, and the tip portion of the welding leg portion 8 is melted.
  • the melting of the welding legs 8 by the hot plate 50 and the melting of the welding projections 6 by the laser irradiation device 60 are, for example, performed and completed at the same time.
  • the welding unit 30 is moved and retracted from between the lamp housing 2 and the cover 3 , and the second jig 80 is moved downward so that the welding legs 8 in the molten state of the cover 3 are removed from the lamp housing 2 . It is pressed against the welding protrusion 6 in the molten state, and the welding protrusion 6 and the welding leg 8 are joined by welding (see FIG. 5).
  • the first jig 70 may be moved upward, or the first jig 70 and the second jig 80 may be vertically moved to press the welding legs 8 against the welding projections 6. .
  • burrs 6b and 8b which are so-called residues on parts, may occur (see FIG. 6).
  • burrs 8b are likely to be generated during melting, and even larger burrs 8b are likely to be formed when joining with the welding protrusion 6 .
  • the width H1 of the welding protrusion 6 is made larger than the width H2 of the welding leg 8, as described above. Therefore, even if a large burr 8b is formed on the welding leg 8, when the welding projection 6 and the welding leg 8 are welded together, the burr 8b is less likely to protrude outward from the welding projection 6 in the width direction. Visibility can be improved when the welded portion is visually recognized through 3 .
  • the lamp housing 2 and the cover 3 are removed from the first jig 70 and the second jig 80 after cooling for a certain period of time. , the joining operation of the lamp housing 2 and the cover 3 by welding is completed.
  • the lamp housing 2 and the cover 3 form a lamp housing 9 (see FIG. 1).
  • the interior of the lamp housing 9 is formed as a lamp chamber 9a, and the vehicle lamp 1 is configured by disposing a lamp unit (not shown) having required parts such as a light source and a reflector in the lamp chamber 9a.
  • a lamp unit not shown
  • the light emitted from the light source is transmitted through the cover 3 and emitted to the outside.
  • the welding leg 8 is heated by the hot plate 50 while the cover-side joint surface 8a of the welding leg 8 and the heat transfer surface 52a of the heat transfer protrusion 52 are in contact with each other. It is also possible to heat the welding leg portion 8 by the hot plate 50 in a non-contact state between the cover-side joint surface 8a and the heat transfer surface 52a. In this case, the welding leg 8 is heated by the hot plate 50 at a high temperature of about 500 degrees, for example, in a state where there is a slight gap between the cover-side joint surface 8a and the heat transfer surface 52a.
  • the tip of the welding leg 8 is sufficiently melted.
  • the welding leg 8 Since the welding leg 8 is heated in a non-contact state with the hot plate 50 , the welding leg 8 is melted without the hot plate 50 coming into contact with the welding leg 8 . A good melting state of the welding leg 8 can be ensured without the occurrence of so-called stringing in which part of the welding leg 8 melted adheres to the hot plate 50 when the welding leg 8 is separated from the part 8 .
  • the welding projection 6 of the lamp housing 2 is irradiated with laser light by the laser irradiation device 60 . It is also possible to use a configuration in which the welding protrusion 6 is not provided. In this case, the welding protrusion 6 does not exist on the lamp housing 2, and the flange portion 5 is irradiated with the laser beam. Accordingly, the flange portion 5 is provided as a weld joint portion 10, and the melted flange portion 5 and the melted weld leg portion 8 are joined.
  • the welding protrusion 6 projecting from the flange portion 5 is provided as the welding joint portion 10 as described above, the flange portion 5 is not melted by the laser beam, so that the thickness of the flange portion 5 can be reduced. Therefore, high strength of the flange portion 5 can be ensured.
  • the projecting portion 6 for welding from the flange portion 5 serves as an index of the irradiation position of the laser beam, and the laser beam is used for welding.
  • the bonding portion 10 can be accurately irradiated.
  • the cover 3 is provided with the design surface portion 7 and the welding leg portion 8, and the lamp housing 2 is provided with the welding joint portion 10 (the welding projection portion 6 or the flange portion 5). was provided, and the welding leg portion 8 melted by the heating of the hot plate 50 and the welding joint portion 10 melted by the irradiation of the laser beam were joined.
  • the welding joint 10 is not melted by the hot plate 50, and the welding joint 10 and the welding leg 8 are individually melted without being in contact with each other, so that the welding joint 10 is heated by the hot plate.
  • a stable joining state between the lamp housing 2 and the cover 3 can be ensured without increasing the manufacturing cost.
  • the welding leg portion 8 projecting from the design surface portion 7 of the cover 3 is melted by the heating of the hot plate 50, and the welding joint portion is irradiated with laser light in the lamp housing 2.
  • 10 welding protrusion 6 or flange 5
  • the lamp housing 2 and the cover 3 is moved toward the other to join the welding leg 8 and the welding joint 10. Therefore, As with the vehicle lamp 1, there is no need to perform mold release treatment with a coating to prevent stringing, and there is no risk of insufficient heat conduction, resulting in an increase in manufacturing costs. Therefore, a stable joining state between the lamp housing 2 and the cover 3 can be ensured.
  • the flange portion 5 is often irradiated with the laser beam R transmitted through the outer peripheral portion 7b of the design surface portion 7 while the portion 7b and the flange portion 5 of the lamp housing 2 are in contact with each other.
  • the cover 3 is pressed against the lamp housing 2 in the vertical direction V, and the outer peripheral portion 7b is pressed against the flange portion 5.
  • the inclination angle P of the outer peripheral portion 7b with respect to the horizontal direction is too large, A sufficient pressing force against the flange portion 5 may not be ensured, and a gap may occur between the outer peripheral portion 7 b and the flange portion 5 . Therefore, the inclination angle P of the outer peripheral portion 7b with respect to the horizontal direction must be within a certain angle, for example, within 30 degrees.
  • the cover 3 is melted by the heat plate 50 and the lamp housing 2 is melted by the irradiation of the laser beam. Since no light is emitted, it is possible to increase the inclination angle P of the outer peripheral portion 7b of the design surface portion 7 with respect to the horizontal direction. Therefore, the degree of freedom in the shape of the lamp housing 2 to which the cover 3 is joined is increased, and the degree of freedom in designing the vehicle lamp 1 can be improved.
  • the outer peripheral portion 7b of the design surface portion 7 can be made of a dark material such as black, or the outer peripheral portion 7b of the design surface portion 7 can be colored dark.
  • the outer peripheral portion 7b of the design surface portion 7 By making the outer peripheral portion 7b of the design surface portion 7 dark in this way, unnecessary light emitted from the light source can be shielded by the outer peripheral portion 7b, thereby preventing irradiation of unnecessary light.
  • the design of the vehicle lamp 1 By darkening the outer peripheral portion 7b of the surface portion 7, the design of the vehicle lamp 1 can be improved.
  • the internal structure is difficult to be visually recognized when the vehicle lamp 1 is visually recognized from the outside through the cover 3, and it is possible to further improve the design.
  • the welding joint 10 of the lamp housing 2 is melted by the irradiation of the laser beam, by changing the irradiation angle and the irradiation position of the laser beam for each product to be manufactured, different types of products can be manufactured on the same production line. It becomes possible to perform a so-called changeover to manufacture different products, and the manufacturing cost of the vehicle lamp 1 can be reduced. In addition, in the manufacture of the lamp housing 2, it is not necessary to use heat plates of different shapes and sizes for each manufactured product, so that the manufacturing cost of the vehicle lamp 1 can be further reduced.
  • the laser head is fixed and the laser beam is irradiated by the galvano laser irradiation device that operates the mirror, the laser beam is repeatedly circulated on the housing side joint surface 6a of the welding protrusion 6 at high speed. It becomes possible to irradiate light, and the entire housing-side joint surface 6a can be heated at the same time, so that the working efficiency in the melting operation can be improved.

Abstract

This lamp fixture for a vehicle comprises a lamp housing with an interior space and a cover that covers the interior space, the cover and the lamp housing being joined by welding, wherein: the cover is provided with a design surface section, an outer surface of which faces outward from the vehicle, and a welding leg section that protrudes from the design surface section; the lamp housing is provided with a joining section for welding that is joined to the welding leg section; and the welding leg section, melted by heating of a heating plate, and the joining section for welding, melted by irradiation with laser light, are joined. Due to the foregoing, melting is performed separately in a state in which the joining section for welding is not melted by the heating plate and the joining section for welding and the welding leg section do not abut one another, so a stable joining state of the lamp housing and the cover can be maintained without a steep rise in manufacturing costs.

Description

車輌用灯具及び車輌用灯具の製造方法VEHICLE LAMP AND METHOD FOR MANUFACTURING VEHICLE LAMP
　本発明は、ランプハウジングとカバーが溶着によって接合される車輌用灯具及び車輌用灯具の製造方法についての技術分野に関する。 The present invention relates to a technical field of a vehicle lamp in which a lamp housing and a cover are joined by welding and a method for manufacturing the vehicle lamp.
　車輌用灯具は、一般に、開口を有するランプハウジングと開口を閉塞するカバーとを有し、ランプハウジングとカバーが接合されて灯具外筐が構成され、灯具外筐の内部にランプユニット等の所要の各部が配置されている。 A vehicle lamp generally has a lamp housing having an opening and a cover that closes the opening. Each part is arranged.
　このような車輌用灯具においては、ランプハウジングとカバーを接合する方法としてホットメルトを用いた接着による方法があるが、ランプハウジングとホットメルトの分離が困難であり、近年、資源のリサイクルの観点から溶着によりランプハウジングとカバーが接合されることも多くなっている。 In such a vehicle lamp, there is a method of bonding the lamp housing and the cover by means of adhesion using hot melt, but it is difficult to separate the lamp housing and the hot melt. Welding is also often used to join the lamp housing and the cover.
　ランプハウジングとカバーを溶着により接合する方法には熱板溶着による方法がある（例えば、特許文献１参照）。熱板溶着による方法は高い溶着強度が確保されると共に接着剤等の消耗材が必要なく、対象となる樹脂の選択の範囲が広く三次元形状の製品の接合に適する等の利点を有している。 There is a hot plate welding method for joining the lamp housing and the cover by welding (see, for example, Patent Document 1). The hot plate welding method has the advantages of ensuring high welding strength, not requiring consumables such as adhesives, and having a wide range of resins to choose from, making it suitable for joining three-dimensional products. there is
　熱板溶着によりランプハウジングとカバーが接合される場合には、ランプハウジングに溶着用接合部が設けられ、カバーには意匠面部における外周部から突出された溶着脚部が設けられる。意匠面部は外面が車輌の外方を向く部分であり、溶着脚部は溶着用接合部に熱板溶着によって接合される部分である。 When the lamp housing and the cover are joined by hot plate welding, the lamp housing is provided with a welding joint portion, and the cover is provided with a welding leg portion projecting from the outer peripheral portion of the design surface portion. The design surface portion is a portion whose outer surface faces the outside of the vehicle, and the welding leg portion is a portion that is joined to the welding joint portion by hot plate welding.
　熱板溶着によるランプハウジングとカバーの接合は、ランプハウジングとカバーがそれぞれ第１の治具と第２の治具によって保持された状態において溶着用接合部と溶着脚部がそれぞれランプハウジング側の熱板とカバー側の熱板とによって溶融され、ランプハウジングとカバーから双方の熱板が退避され、第２の治具が第１の治具に近付く方向へ移動されることにより行われる。第２の治具が第１の治具に近付く方向へ移動されることにより、溶着脚部の溶融部分が溶着用接合部の溶融部分に押し付けられ、溶着脚部と溶着用接合部が溶着により接合される。 When the lamp housing and cover are joined by hot plate welding, the lamp housing and cover are held by a first jig and a second jig, respectively, and the welding joints and welding legs are heated by heating the lamp housing side. The hot plate is melted by the plate and the hot plate on the cover side, both hot plates are withdrawn from the lamp housing and the cover, and the second jig is moved toward the first jig. By moving the second jig in a direction approaching the first jig, the melted portion of the welding leg is pressed against the melted portion of the welding joint, and the welding leg and the welding joint are welded together. spliced.
特開２０１２－２０１０１５号公報Japanese Unexamined Patent Application Publication No. 2012-201015
　ところで、ランプハウジングは、一般に、製造コストや入手の容易性等を考慮してアクリロニトリル・ブタジエン・スチレン樹脂（ＡＢＳ：Acrylonitrile Butadiene Styrene）やアクリロ二トリル・スチレン樹脂 (ＡＳ：Acrylonitrile Styrene)等の樹脂材料によって形成される。 By the way, the lamp housing is generally made of a resin material such as acrylonitrile butadiene styrene (ABS) or acrylonitrile styrene (AS) in consideration of manufacturing cost and availability. formed by
　ところが、これらの樹脂材料においては、特性上、熱板を溶着用接合部に接触させて溶融を行う場合に、熱板が溶着脚部から離れるときに溶融された溶着用接合部の一部が熱板に付着される所謂糸引きが生じるおそれがある。 However, due to the characteristics of these resin materials, when the hot plate is brought into contact with the welding joint to melt, part of the welding joint that is melted when the hot plate separates from the welding leg is There is a risk of so-called stringing that sticks to the hot plate.
　そこで、熱板の溶着用接合部との接触部分にフッ素樹脂のコーティングを形成して離型処理を施し、コーティングを介して熱板を溶着用接合部に接触させることにより糸引きの発生を防止することが行われている。 Therefore, a fluororesin coating is formed on the contact portion of the hot plate with the joint for welding, and release treatment is applied. By bringing the hot plate into contact with the joint for welding through the coating, stringiness is prevented. is being done.
　しかしながら、コーティングによる離型処理は、繰り返し行われる溶融作業における熱と圧力によって劣化が生じるため、一定期間の経過毎にコーティングの再形成が必要になり、その分、車輌用灯具の製造コストが高くなってしまう。また、一定期間の経過毎のコーティングの再形成を行うと再形成の間に溶融作業を行うことができず、熱板の稼働率が低下するため、コーティングが形成されている別の熱板を予め用意しておく場合もあるが、この場合には熱板が複数必要になり、やはり車輌用灯具の製造コストが高くなってしまう。 However, the mold release process using coating deteriorates due to the heat and pressure in the repeated melting process, so the coating needs to be re-formed after a certain period of time, which increases the manufacturing cost of the vehicle lamp. turn into. In addition, if the coating is re-formed every certain period of time, the melting operation cannot be performed during the re-forming, and the operating rate of the hot plate decreases. In some cases, they are prepared in advance, but in this case, a plurality of hot plates are required, which also increases the manufacturing cost of the vehicle lamp.
　一方、ランプハウジングとカバーをレーザー光の照射により接合する方法もある。レーザー光による方法は、溶着脚部と溶着用接合部が接した状態においてレーザー光がカバーを透過されてランプハウジングの溶着用接合部に照射され、レーザー光によって溶着用接合部を溶融させると共に溶着用接合部に達したレーザー光の熱を溶着用接合部から溶着脚部に伝導させて溶着脚部を溶融させ、溶着用接合部と溶着脚部が溶着されることにより行われる。 On the other hand, there is also a method of joining the lamp housing and cover by irradiating laser light. In the method using a laser beam, a laser beam is transmitted through the cover while the welding leg and the welding joint are in contact with each other, and the welding joint of the lamp housing is irradiated with the laser beam. The heat of the laser beam reaching the welding joint is conducted from the welding joint to the welding leg to melt the welding leg, thereby welding the welding joint and the welding leg.
　しかしながら、溶着脚部と溶着用接合部の加工精度等によって両者の間に隙間が生じた状態でレーザー光が照射される可能性があり、この場合には溶着用接合部から溶着脚部への熱の伝導が不十分になり、溶着用接合部と溶着脚部の溶着状態が不安定になるおそれがある。 However, depending on the processing accuracy of the welding leg and welding joint, there is a possibility that the laser beam will be irradiated with a gap between them. Heat conduction becomes insufficient, and the welding state between the welding joint and the welding leg may become unstable.
　そこで、本発明車輌用灯具及び車輌用灯具の製造方法は、製造コストの高騰を来すことなくランプハウジングとカバーの安定した接合状態を確保することを目的とする。 Therefore, the object of the vehicle lamp and the method for manufacturing the vehicle lamp of the present invention is to ensure a stable joint state between the lamp housing and the cover without increasing the manufacturing cost.
　第１に、本発明に係る車輌用灯具は、内部空間を有するランプハウジングと前記内部空間を覆うカバーとを備え前記カバーと前記ランプハウジングが溶着によって接合される車輌用灯具であって、前記カバーには外面が車輌の外方を向く意匠面部と前記意匠面部から突出された溶着脚部とが設けられ、前記ランプハウジングには前記溶着脚部と接合される溶着用接合部が設けられ、熱板の加熱によって溶融された前記溶着脚部とレーザー光の照射によって溶融された前記溶着用接合部とが接合されるものである。 First, a vehicle lamp according to the present invention is a vehicle lamp including a lamp housing having an internal space and a cover covering the internal space, wherein the cover and the lamp housing are joined by welding, the cover The lamp housing is provided with a design surface part whose outer surface faces the outside of the vehicle and a welding leg part projecting from the design surface part, and the lamp housing is provided with a welding joint part that is joined to the welding leg part, and heats the lamp housing. The welding leg portion melted by heating the plate and the welding joint portion melted by laser beam irradiation are joined together.
　これにより、溶着用接合部が熱板によって溶融されないと共に溶着用接合部と溶着脚部が接しない状態で各別に溶融される。 As a result, the welding joints are not melted by the hot plate, and the welding joints and the welding legs are individually melted without being in contact with each other.
　第２に、上記した本発明に係る車輌用灯具においては、前記ランプハウジングに前記内部空間を有する本体部と前記本体部の外周部から外方に張り出されたフランジ部とが設けられ、前記溶着用接合部として前記フランジ部から突出された溶着用突部が設けられることが望ましい。 Secondly, in the above-described vehicle lamp according to the present invention, the lamp housing is provided with a main body portion having the internal space and a flange portion projecting outward from the outer peripheral portion of the main body portion. It is preferable that a welding protrusion projecting from the flange portion is provided as the welding joint.
　これにより、レーザー光によってフランジ部が溶融されないため、フランジ部の厚みが薄くならない。 As a result, the flange is not melted by the laser beam, so the thickness of the flange is not reduced.
　第３に、上記した本発明に係る車輌用灯具においては、前記溶着用突部の幅が前記溶着脚部の幅より大きくされることが望ましい。 Thirdly, in the above-described vehicle lamp according to the present invention, it is desirable that the width of the welding protrusion be larger than the width of the welding leg.
　これにより、溶着脚部に大きなバリが生じた場合でも溶着用突部と溶着脚部が溶着されたときにバリが幅方向において溶着用突部から外側に突出され難い。 As a result, even if a large burr occurs on the welding leg, the burr is less likely to protrude outward from the welding protrusion in the width direction when the welding protrusion and the welding leg are welded together.
　第４に、上記した本発明に係る車輌用灯具においては、前記溶着脚部が前記熱板と非接触の状態で加熱されることが望ましい。 Fourthly, in the above-described vehicle lamp according to the present invention, it is desirable that the welding leg portion be heated in a non-contact state with the hot plate.
　これにより、熱板が溶着脚部に接触されることなく溶着脚部が溶融されるため、熱板が溶着脚部から離れるときに溶融された溶着脚部の一部が熱板に付着される所謂糸引きが生じることがない。 As a result, the welding leg is melted without the hot plate coming into contact with the welding leg, so that when the hot plate separates from the welding leg, part of the melted welding leg adheres to the hot plate. So-called stringiness does not occur.
　第５に、本発明に係る車輌用灯具の製造方法は、内部空間を有するランプハウジングと前記内部空間を覆うカバーとが溶着によって接合される車輌用灯具の製造方法であって、前記カバーにおいて外面が車輌の外方を向く意匠面部から突出された溶着脚部が熱板の加熱によって溶融されると共に前記ランプハウジングにおいてレーザー光の照射によって溶着用接合部が溶融され、前記ランプハウジングと前記カバーの少なくとも一方が他方に近付く方向へ移動されて前記溶着脚部と前記溶着用接合部とが接合されるものである。 Fifth, a method for manufacturing a vehicle lamp according to the present invention is a method for manufacturing a vehicle lamp in which a lamp housing having an internal space and a cover covering the internal space are joined by welding, wherein the cover has an outer surface is melted by the heating of the hot plate, and the welding joint portion of the lamp housing is melted by the irradiation of the laser beam, and the lamp housing and the cover are melted. At least one of the legs is moved toward the other to join the welding leg and the welding joint.
　これにより、溶着用接合部が熱板によって溶融されないと共に溶着用接合部と溶着脚部が接しない状態で各別に溶融される。 As a result, the welding joints are not melted by the hot plate, and the welding joints and the welding legs are individually melted without being in contact with each other.
　本発明によれば、溶着用接合部が熱板によって溶融されないと共に溶着用接合部と溶着脚部が接しない状態で各別に溶融されるため、糸引きの発生を防止するための離型処理の実施や予備の熱板を用意する必要がないと共に溶着用接合部と溶着脚部の間に隙間が生じることがなく、製造コストの高騰を来すことなくランプハウジングとカバーの安定した接合状態を確保することができる。 According to the present invention, the welding joints are not melted by the hot plate and the welding joints and the welding legs are individually melted without being in contact with each other. It is not necessary to prepare a heat plate or a spare hot plate, and there is no gap between the welding joint and the welding leg, so that the lamp housing and the cover can be stably joined without increasing the manufacturing cost. can be secured.
図２乃至図７と共に本発明車輌用灯具及び車輌用灯具の製造方法の実施の形態を示すものであり、本図は、車輌用灯具を示す断面図である。FIG. 2 to FIG. 7 show an embodiment of a vehicle lamp and a method for manufacturing a vehicle lamp according to the present invention, and this figure is a cross-sectional view showing the vehicle lamp. 溶着により接合された部分を示す断面図である。FIG. 4 is a cross-sectional view showing a portion joined by welding; 第１の治具に保持されたランプハウジングと第２の治具に保持されたカバーとの間に溶着ユニットが移動された状態を示す断面図である。FIG. 5 is a cross-sectional view showing a state in which the welding unit is moved between the lamp housing held by the first jig and the cover held by the second jig; 図３に引き続き、カバーの溶着脚部が熱板によって加熱されランプハウジングの溶着用突部にレーザー光が照射されている状態を示す断面図である。FIG. 4 is a cross-sectional view, continued from FIG. 3, showing a state in which the welding leg portion of the cover is heated by the hot plate and the welding protrusion of the lamp housing is irradiated with laser light; 図４に引き続き、溶着ユニットが退避されランプハウジングとカバーが接合された状態を示す断面図である。FIG. 5 is a cross-sectional view, continued from FIG. 4 , showing a state in which the welding unit is retracted and the lamp housing and the cover are joined together; 溶着用突部と溶着脚部が接合された状態を示す断面図である。FIG. 4 is a cross-sectional view showing a state in which a welding protrusion and a welding leg are joined; カバーの外周部の傾斜角度等を示す断面図である。FIG. 4 is a cross-sectional view showing an inclination angle and the like of an outer peripheral portion of a cover;
　以下に、本発明車輌用灯具及び車輌用灯具の製造方法を実施するための形態について添付図面を参照して説明する。 Embodiments for carrying out the vehicle lamp and the method for manufacturing the vehicle lamp of the present invention will be described below with reference to the accompanying drawings.
　＜車輌用灯具の構成＞
　先ず、車輌用灯具１の構成について説明する（図１及び図２参照）。 <Structure of vehicle lamp>
First, the configuration of the vehicle lamp 1 will be described (see FIGS. 1 and 2).
　車輌用灯具１はランプハウジング２とカバー３を有し、カバー３がランプハウジング２に溶着によって接合される。以下の説明においては理解を容易にするために、溶着による接合時においてランプハウジング２とカバー３が保持される位置に対応して前後上下左右の方向を示すものとする。従って、カバー３が位置する側を上方とし、ランプハウジング２が位置する側を下方とし、各図に示す断面形状においてカバー３の外周部が位置する方向を便宜上左右方向とする。 A vehicle lamp 1 has a lamp housing 2 and a cover 3, and the cover 3 is joined to the lamp housing 2 by welding. In the following description, for ease of understanding, the front, back, top, bottom, left, and right directions correspond to the positions at which the lamp housing 2 and the cover 3 are held when joined by welding. Accordingly, the side on which the cover 3 is positioned is defined as the upper side, the side where the lamp housing 2 is positioned is defined as the lower side, and the direction in which the outer peripheral portion of the cover 3 is positioned in the cross-sectional shape shown in each drawing is defined as the horizontal direction for convenience.
　但し、以下に示す前後上下左右の方向は説明の便宜上のものであり、本発明の実施に関しては、これらの方向に限定されることはない。 However, the front, rear, up, down, left, and right directions shown below are for convenience of explanation, and the implementation of the present invention is not limited to these directions.
　また、参照する各図には、本発明の理解を容易にするために、例として、車輌用灯具１を回転対称の簡素な形状にして示す。 In addition, in each of the referenced figures, as an example, the vehicle lamp 1 is shown in a simple rotationally symmetrical shape in order to facilitate understanding of the present invention.
　車輌用灯具１は、上記したように、ランプハウジング２とカバー３が溶着によって接合され、ランプハウジング２とカバー３の所定の各部がそれぞれ溶融された状態で圧着されることにより接合される（図１参照）。 In the vehicle lamp 1, as described above, the lamp housing 2 and the cover 3 are joined by welding, and the respective predetermined portions of the lamp housing 2 and the cover 3 are welded and then crimped together (see FIG. 1). 1).
　ランプハウジング２は、例えば、ＡＢＳ樹脂やＡＳ樹脂等の樹脂材料によって形成されている。ランプハウジング２は上方に開口された凹状の本体部４と本体部４の上端部から外方に張り出された環状のフランジ部５とフランジ部５から上方に突出された環状の溶着用突部６とを有している。ランプハウジング２においては本体部４の内側の空間が内部空間４ａとして形成されている。 The lamp housing 2 is made of, for example, a resin material such as ABS resin or AS resin. The lamp housing 2 comprises a concave body portion 4 which is open upward, an annular flange portion 5 projecting outward from the upper end portion of the body portion 4, and an annular welding protrusion projecting upward from the flange portion 5. 6. In the lamp housing 2, the space inside the body portion 4 is formed as an internal space 4a.
　溶着用突部６はカバー３と接合される溶着用接合部１０として設けられ、先端面がハウジング側接合面６ａとして形成されている。溶着用突部６のフランジ部５からの突出量Ｔは小さく、例えば、０．５ｍｍ以上２ｍｍ以下にされ、溶着用突部６の幅Ｈ１は、例えば、２ｍｍ以上４ｍｍ以下にされている。 The welding projection 6 is provided as a welding joint 10 to be joined to the cover 3, and the tip surface thereof is formed as the housing-side joint surface 6a. The projection amount T of the welding projection 6 from the flange portion 5 is small, for example, 0.5 mm or more and 2 mm or less, and the welding projection 6 has a width H1 of, for example, 2 mm or more and 4 mm or less.
　カバー３は、例えば、透明なアクリル等の樹脂材料によって形成され、外面が車輌の外方を向く意匠面部７と意匠面部７の内面７ａにおける外周寄りの部分から突出された溶着脚部８とが一体に形成されて成る。カバー３は内部空間４ａを覆う状態でランプハウジング２に接合される。 The cover 3 is formed of, for example, a resin material such as transparent acrylic, and has a design surface portion 7 whose outer surface faces the outside of the vehicle and welding leg portions 8 protruding from a portion of the interior surface 7a of the design surface portion 7 near the outer periphery. It is integrally formed. The cover 3 is joined to the lamp housing 2 so as to cover the internal space 4a.
　意匠面部７は車体の形状に応じてランプハウジング２の反対側に凸になるように湾曲されており、曲面状に形成されている。溶着脚部８の先端面はカバー側接合面８ａとして形成されている。溶着脚部８は、意匠面部７からの突出量が溶着用突部６の突出量Ｔより小大きくされ、幅Ｈ２が、例えば、１．５ｍｍ以上４ｍｍ以下にされている。従って、溶着用突部６の幅Ｈ１は溶着脚部８の幅Ｈ２より大きくされている。 The design surface portion 7 is curved so as to protrude on the opposite side of the lamp housing 2 according to the shape of the vehicle body, and is formed into a curved surface. The tip surface of the welding leg portion 8 is formed as a cover-side joint surface 8a. The welding leg portion 8 has a projection amount slightly larger than the projection amount T of the welding protrusion 6 from the design surface portion 7, and has a width H2 of, for example, 1.5 mm or more and 4 mm or less. Therefore, the width H1 of the welding projection 6 is made larger than the width H2 of the welding leg 8. As shown in FIG.
　＜溶着ユニットの構成＞
　次に、ランプハウジング２とカバー３を接合する溶着ユニット３０の構成について説明する（図３参照）。 <Structure of welding unit>
Next, the construction of the welding unit 30 that joins the lamp housing 2 and the cover 3 will be described (see FIG. 3).
　溶着ユニット３０は、例えば、平板状のベース４０とベース４０の上面に配置された熱板５０とベース４０の下面に配置されたレーザー照射装置６０とを有している。 The welding unit 30 has, for example, a flat base 40 , a hot plate 50 arranged on the upper surface of the base 40 , and a laser irradiation device 60 arranged on the lower surface of the base 40 .
　熱板５０にはベース４０に取り付けられた熱板本体５１と熱板本体５１から上方に突出された環状の伝熱突部５２とを有している。伝熱突部５２の先端面は伝熱面５２ａとして形成されている。 The hot plate 50 has a hot plate main body 51 attached to the base 40 and an annular heat transfer protrusion 52 protruding upward from the hot plate main body 51 . A tip surface of the heat transfer protrusion 52 is formed as a heat transfer surface 52a.
　レーザー照射装置６０からはランプハウジング２の溶着用突部６に形成されたハウジング側接合面６ａへ向けてレーザー光が照射される。レーザー照射装置６０は、レーザーヘッドが照射位置に応じた位置に移動してレーザー光の照射を行うプロッター式の所謂ＸＹレーザー照射装置であってもよく、レーザーヘッドが固定されミラーを動作させて照射位置へ向けてレーザー光の照射を行う所謂ガルバノレーザー照射装置であってもよい。 A laser beam is emitted from the laser irradiation device 60 toward the housing-side joint surface 6 a formed on the welding protrusion 6 of the lamp housing 2 . The laser irradiation device 60 may be a plotter-type so-called XY laser irradiation device in which the laser head moves to a position corresponding to the irradiation position to irradiate the laser light. A so-called galvano laser irradiation device that irradiates a laser beam toward a position may be used.
　＜接合作業の手順＞
　以下に、ランプハウジング２とカバー３の溶着による接合作業の手順について簡単に説明する（図３乃至図６参照）。 <Joining procedure>
A procedure for joining the lamp housing 2 and the cover 3 by welding will be briefly described below (see FIGS. 3 to 6).
　溶着によるランプハウジング２とカバー３の接合時には、ランプハウジング２とカバー３がそれぞれ第１の治具７０と第２の治具８０によって保持され、カバー３がランプハウジング２の上方において離隔して位置される。 When the lamp housing 2 and the cover 3 are joined by welding, the lamp housing 2 and the cover 3 are held by the first jig 70 and the second jig 80, respectively, and the cover 3 is positioned above the lamp housing 2 with a space therebetween. be done.
　次に、ランプハウジング２とカバー３がそれぞれ第１の治具７０と第２の治具８０によって保持された状態において、ランプハウジング２とカバー３の間に溶着ユニット３０が移動される（図３参照）。 Next, while the lamp housing 2 and the cover 3 are held by the first jig 70 and the second jig 80, respectively, the welding unit 30 is moved between the lamp housing 2 and the cover 3 (see FIG. 3). reference).
　ランプハウジング２とカバー３の間に溶着ユニット３０が移動されると、例えば、第２の治具８０が下方へ移動されてカバー３の溶着脚部８に形成されたカバー側接合面８ａが熱板５０の伝熱突部５２に形成された伝熱面５２ａに突き当てられる（図４参照）。カバー側接合面８ａが伝熱面５２ａに突き当てられて接した状態にされると、熱板５０によって溶着脚部８が加熱され、溶着脚部８の先端部が溶融される。 When the welding unit 30 is moved between the lamp housing 2 and the cover 3, for example, the second jig 80 is moved downward so that the cover-side joint surfaces 8a formed on the welding legs 8 of the cover 3 are heated. It abuts against the heat transfer surface 52a formed on the heat transfer protrusion 52 of the plate 50 (see FIG. 4). When the cover-side joint surface 8a is brought into contact with the heat transfer surface 52a, the welding leg portion 8 is heated by the hot plate 50, and the tip portion of the welding leg portion 8 is melted.
　一方、ランプハウジング２とカバー３の間に溶着ユニット３０が移動されると、レーザー照射装置６０からランプハウジング２の溶着用突部６に形成されたハウジング側接合面６ａへ向けてレーザー光が照射され、溶着用突部６の先端部が溶融される。 On the other hand, when the welding unit 30 is moved between the lamp housing 2 and the cover 3, a laser beam is emitted from the laser irradiation device 60 toward the housing-side joint surface 6a formed on the welding protrusion 6 of the lamp housing 2. and the tip of the welding protrusion 6 is melted.
　熱板５０による溶着脚部８の溶融とレーザー照射装置６０による溶着用突部６の溶融とは、例えば、同時に行われ、同時に終了される。 The melting of the welding legs 8 by the hot plate 50 and the melting of the welding projections 6 by the laser irradiation device 60 are, for example, performed and completed at the same time.
　次いで、溶着ユニット３０が移動されてランプハウジング２とカバー３の間から退避されると共に第２の治具８０が下方へ移動されてカバー３の溶融状態にある溶着脚部８がランプハウジング２の溶融状態にある溶着用突部６に押し付けられ、溶着用突部６と溶着脚部８が溶着により接合される（図５参照）。尚、このとき第１の治具７０が上方へ移動され又は第１の治具７０と第２の治具８０が上下動されて溶着脚部８が溶着用突部６に押し付けられてもよい。 Next, the welding unit 30 is moved and retracted from between the lamp housing 2 and the cover 3 , and the second jig 80 is moved downward so that the welding legs 8 in the molten state of the cover 3 are removed from the lamp housing 2 . It is pressed against the welding protrusion 6 in the molten state, and the welding protrusion 6 and the welding leg 8 are joined by welding (see FIG. 5). At this time, the first jig 70 may be moved upward, or the first jig 70 and the second jig 80 may be vertically moved to press the welding legs 8 against the welding projections 6. .
　溶着用突部６と溶着脚部８は何れも溶融された状態で押し付けられて接合されるため、溶着用突部６の先端部と溶着脚部８の先端部とが外方に膨らむ状態の所謂部品上の残留物であるバリ６ｂとバリ８ｂが生じることがある（図６参照）。特に、熱板５０によって溶融される溶着脚部８は溶融時に加圧されるため、溶融時にもバリ８ｂが生じ易く、溶着用突部６との接合時にさらに大きなバリ８ｂが形成され易い。 Since the welding protrusion 6 and the welding leg 8 are pressed together in a molten state, the tip of the welding protrusion 6 and the tip of the welding leg 8 bulge outward. Burrs 6b and 8b, which are so-called residues on parts, may occur (see FIG. 6). In particular, since the welding leg portion 8 melted by the hot plate 50 is pressurized during melting, burrs 8b are likely to be generated during melting, and even larger burrs 8b are likely to be formed when joining with the welding protrusion 6 .
　しかしながら、車輌用灯具１においては、上記したように、溶着用突部６の幅Ｈ１が溶着脚部８の幅Ｈ２より大きくされている。従って、溶着脚部８に大きなバリ８ｂが生じた場合でも溶着用突部６と溶着脚部８が溶着されたときにバリ８ｂが幅方向において溶着用突部６から外側に突出され難く、カバー３を通して溶着部分が視認されたときの被視認性の向上を図ることができる。 However, in the vehicle lamp 1, the width H1 of the welding protrusion 6 is made larger than the width H2 of the welding leg 8, as described above. Therefore, even if a large burr 8b is formed on the welding leg 8, when the welding projection 6 and the welding leg 8 are welded together, the burr 8b is less likely to protrude outward from the welding projection 6 in the width direction. Visibility can be improved when the welded portion is visually recognized through 3 .
　上記のように、溶着用突部６と溶着脚部８が接合されると、一定時間の冷却後にランプハウジング２とカバー３がそれぞれ第１の治具７０と第２の治具８０から取り出され、溶着によるランプハウジング２とカバー３の接合作業が終了する。 After the welding protrusion 6 and the welding leg 8 are joined as described above, the lamp housing 2 and the cover 3 are removed from the first jig 70 and the second jig 80 after cooling for a certain period of time. , the joining operation of the lamp housing 2 and the cover 3 by welding is completed.
　ランプハウジング２とカバー３が接合されることによりランプハウジング２とカバー３によって灯具外筐９が構成される（図１参照）。灯具外筐９の内部は灯室９ａとして形成され、灯室９ａには光源やリフレクター等の所要の各部を有する図示しない灯具ユニットが配置されて車輌用灯具１が構成される。車輌用灯具１において、光源から出射された光はカバー３を透過され外部へ向けて照射される。 By joining the lamp housing 2 and the cover 3 together, the lamp housing 2 and the cover 3 form a lamp housing 9 (see FIG. 1). The interior of the lamp housing 9 is formed as a lamp chamber 9a, and the vehicle lamp 1 is configured by disposing a lamp unit (not shown) having required parts such as a light source and a reflector in the lamp chamber 9a. In the vehicle lamp 1, the light emitted from the light source is transmitted through the cover 3 and emitted to the outside.
　上記には、熱板５０による溶着脚部８の加熱が溶着脚部８のカバー側接合面８ａと伝熱突部５２の伝熱面５２ａとが接した状態で行われる例を示したが、熱板５０による溶着脚部８の加熱がカバー側接合面８ａと伝熱面５２ａが非接触の状態で行われるようにすることも可能である。この場合には、カバー側接合面８ａと伝熱面５２ａの間に僅かな隙間を有する状態において、例えば、５００度程度の高温で熱板５０による溶着脚部８に対する加熱が行われる。 In the above example, the welding leg 8 is heated by the hot plate 50 while the cover-side joint surface 8a of the welding leg 8 and the heat transfer surface 52a of the heat transfer protrusion 52 are in contact with each other. It is also possible to heat the welding leg portion 8 by the hot plate 50 in a non-contact state between the cover-side joint surface 8a and the heat transfer surface 52a. In this case, the welding leg 8 is heated by the hot plate 50 at a high temperature of about 500 degrees, for example, in a state where there is a slight gap between the cover-side joint surface 8a and the heat transfer surface 52a.
　このような高温で熱板５０による溶着脚部８に対する加熱が行われることにより、溶着脚部８の先端部が十分に溶融される。 By heating the welding leg 8 by the hot plate 50 at such a high temperature, the tip of the welding leg 8 is sufficiently melted.
　溶着脚部８が熱板５０と非接触の状態で加熱されることにより、熱板５０が溶着脚部８に接触されることなく溶着脚部８が溶融されるため、熱板５０が溶着脚部８から離れるときに溶融された溶着脚部８の一部が熱板５０に付着される所謂糸引きが生じることがなく、溶着脚部８の良好な溶融状態を確保することができる。 Since the welding leg 8 is heated in a non-contact state with the hot plate 50 , the welding leg 8 is melted without the hot plate 50 coming into contact with the welding leg 8 . A good melting state of the welding leg 8 can be ensured without the occurrence of so-called stringing in which part of the welding leg 8 melted adheres to the hot plate 50 when the welding leg 8 is separated from the part 8 .
　また、上記には、レーザー照射装置６０によるレーザー光の照射がランプハウジング２の溶着用突部６に対して行われる例を示したが、レーザー照射装置６０によるレーザー光の照射がランプハウジング２に溶着用突部６が設けられていない構成で行われるようにすることも可能である。この場合には、ランプハウジング２には溶着用突部６が存在せず、フランジ部５に対してレーザー光が照射される。従って、フランジ部５は溶着用接合部１０として設けられ、溶融されたフランジ部５と溶融された溶着脚部８とが接合される。 In the above, an example is shown in which the welding projection 6 of the lamp housing 2 is irradiated with laser light by the laser irradiation device 60 . It is also possible to use a configuration in which the welding protrusion 6 is not provided. In this case, the welding protrusion 6 does not exist on the lamp housing 2, and the flange portion 5 is irradiated with the laser beam. Accordingly, the flange portion 5 is provided as a weld joint portion 10, and the melted flange portion 5 and the melted weld leg portion 8 are joined.
　但し、この場合に、フランジ部５の一部が溶融されることによりフランジ部５の厚みが薄くなり、フランジ部５の十分な強度を確保することができなくなる可能性がある。 However, in this case, a portion of the flange portion 5 is melted to reduce the thickness of the flange portion 5, and there is a possibility that sufficient strength of the flange portion 5 cannot be ensured.
　従って、上記のように、溶着用接合部１０としてフランジ部５から突出された溶着用突部６が設けられることにより、レーザー光によってフランジ部５が溶融されないため、フランジ部５の厚みが薄くならず、フランジ部５の高い強度を確保することができる。また、フランジ部５から突出された部分がレーザー光の照射対象になるため、フランジ部５から溶着用突部６が突出されることによりレーザー光の照射位置の指標になり、レーザー光を溶着用接合部１０に対して正確に照射することができる。 Therefore, since the welding protrusion 6 projecting from the flange portion 5 is provided as the welding joint portion 10 as described above, the flange portion 5 is not melted by the laser beam, so that the thickness of the flange portion 5 can be reduced. Therefore, high strength of the flange portion 5 can be ensured. In addition, since the portion protruding from the flange portion 5 is to be irradiated with the laser beam, the projecting portion 6 for welding from the flange portion 5 serves as an index of the irradiation position of the laser beam, and the laser beam is used for welding. The bonding portion 10 can be accurately irradiated.
　＜まとめ＞
　以上に記載した通り、車輌用灯具１にあっては、カバー３に意匠面部７と溶着脚部８が設けられ、ランプハウジング２に溶着用接合部１０（溶着用突部６又はフランジ部５）が設けられ、熱板５０の加熱によって溶融された溶着脚部８とレーザー光の照射によって溶融された溶着用接合部１０とが接合された。 <Summary>
As described above, in the vehicle lamp 1, the cover 3 is provided with the design surface portion 7 and the welding leg portion 8, and the lamp housing 2 is provided with the welding joint portion 10 (the welding projection portion 6 or the flange portion 5). was provided, and the welding leg portion 8 melted by the heating of the hot plate 50 and the welding joint portion 10 melted by the irradiation of the laser beam were joined.
　従って、溶着用接合部１０においては熱板５０によって溶融されないと共に溶着用接合部１０と溶着脚部８が接しない状態で各別に溶融されるため、溶着用接合部１０が熱板によって加熱される場合のような糸引きを防止するためのコーティングによる離型処理を行う必要がなく、また、ランプハウジング２とカバー３をレーザー光の照射により接合する場合のような両者の間に隙間が生じた場合の熱の不十分な伝導と言う不具合を生じるおそれもない。これにより、製造コストの高騰を来すことなくランプハウジング２とカバー３の安定した接合状態を確保することができる。 Therefore, the welding joint 10 is not melted by the hot plate 50, and the welding joint 10 and the welding leg 8 are individually melted without being in contact with each other, so that the welding joint 10 is heated by the hot plate. There is no need to perform a release treatment by coating to prevent stringiness, and a gap is created between the lamp housing 2 and the cover 3 as in the case where they are joined by laser light irradiation. Insufficient conduction of heat in the case is also not likely to occur. As a result, a stable joining state between the lamp housing 2 and the cover 3 can be ensured without increasing the manufacturing cost.
　また、車輌用灯具１の製造方法においては、カバー３において意匠面部７から突出された溶着脚部８が熱板５０の加熱によって溶融されると共にランプハウジング２においてレーザー光の照射によって溶着用接合部１０（溶着用突部６又はフランジ部５）が溶融され、ランプハウジング２とカバー３の少なくとも一方が他方に近づく方向へ移動されて溶着脚部８と溶着用接合部１０が接合される
　従って、車輌用灯具１と同様に、糸引きを防止するためのコーティングによる離型処理を行う必要がないと共に熱の不十分な伝導と言う不具合を生じるおそれもないため、製造コストの高騰を来すことなくランプハウジング２とカバー３の安定した接合状態を確保することができる。 In the manufacturing method of the vehicle lamp 1, the welding leg portion 8 projecting from the design surface portion 7 of the cover 3 is melted by the heating of the hot plate 50, and the welding joint portion is irradiated with laser light in the lamp housing 2. 10 (welding protrusion 6 or flange 5) is melted, and at least one of the lamp housing 2 and the cover 3 is moved toward the other to join the welding leg 8 and the welding joint 10. Therefore, As with the vehicle lamp 1, there is no need to perform mold release treatment with a coating to prevent stringing, and there is no risk of insufficient heat conduction, resulting in an increase in manufacturing costs. Therefore, a stable joining state between the lamp housing 2 and the cover 3 can be ensured.
　さらに、レーザー光の照射によってランプハウジング２とカバー３が接合される場合には、図７に示すように、溶着用突部６と溶着脚部８が存在せずカバー３における意匠面部７の外周部７ｂとランプハウジング２のフランジ部５とが接した状態で意匠面部７の外周部７ｂを透過されたレーザー光Ｒがフランジ部５に照射されることが多い。このとき、カバー３はランプハウジング２に対して垂直方向Ｖから押さえられて外周部７ｂがフランジ部５に押し付けられるが、外周部７ｂの水平方向に対する傾斜角度Ｐが大き過ぎると、外周部７ｂのフランジ部５に対する十分な押付力が確保されず外周部７ｂとフランジ部５の間に隙間が生じるおそれがある。従って、外周部７ｂの水平方向に対する傾斜角度Ｐは一定の角度以内、例えば、３０度以内の角度にされる必要がある。 Furthermore, when the lamp housing 2 and the cover 3 are joined by irradiation of laser light, as shown in FIG. The flange portion 5 is often irradiated with the laser beam R transmitted through the outer peripheral portion 7b of the design surface portion 7 while the portion 7b and the flange portion 5 of the lamp housing 2 are in contact with each other. At this time, the cover 3 is pressed against the lamp housing 2 in the vertical direction V, and the outer peripheral portion 7b is pressed against the flange portion 5. However, if the inclination angle P of the outer peripheral portion 7b with respect to the horizontal direction is too large, A sufficient pressing force against the flange portion 5 may not be ensured, and a gap may occur between the outer peripheral portion 7 b and the flange portion 5 . Therefore, the inclination angle P of the outer peripheral portion 7b with respect to the horizontal direction must be within a certain angle, for example, within 30 degrees.
　一方、車輌用灯具１においては、カバー３が熱板５０によって溶融されランプハウジング２がレーザー光の照射によって溶融されるため、意匠面部７の外周部７ｂがフランジ部５に押し付けられた状態でレーザー光の照射が行われることがなく、その分、意匠面部７の外周部７ｂの水平方向に対する傾斜角度Ｐを大きくすることが可能である。従って、カバー３とカバー３が接合されるランプハウジング２の形状の自由度が大きくなり、車輌用灯具１における設計の自由度の向上を図ることができる。 On the other hand, in the vehicle lamp 1, the cover 3 is melted by the heat plate 50 and the lamp housing 2 is melted by the irradiation of the laser beam. Since no light is emitted, it is possible to increase the inclination angle P of the outer peripheral portion 7b of the design surface portion 7 with respect to the horizontal direction. Therefore, the degree of freedom in the shape of the lamp housing 2 to which the cover 3 is joined is increased, and the degree of freedom in designing the vehicle lamp 1 can be improved.
　また、レーザー光が意匠面部７の外周部７ｂを透過される作業が行われることなくランプハウジング２とカバー３が接合されるため、意匠面部７の外周部７ｂをレーザー光が透過される構成にする必要がなく、意匠面部７の外周部７ｂを暗色、例えば、黒色の材料によって形成したり、意匠面部７の外周部７ｂを暗色に着色することが可能になる。 In addition, since the lamp housing 2 and the cover 3 are joined without the work of transmitting the laser light through the outer peripheral portion 7b of the design surface portion 7, the laser light is transmitted through the outer peripheral portion 7b of the design surface portion 7. Therefore, the outer peripheral portion 7b of the design surface portion 7 can be made of a dark material such as black, or the outer peripheral portion 7b of the design surface portion 7 can be colored dark.
　このように意匠面部７の外周部７ｂを暗色にすることにより光源から出射される光のうち不要な光を外周部７ｂによって遮蔽して不要光の照射の防止を図ることができ、また、意匠面部７の外周部７ｂを暗色にすることにより車輌用灯具１の意匠性の向上を図ることができる。また、意匠面部７の外周部７ｂを暗色にすることにより、外部からカバー３を通して車輌用灯具１が視認されるときに内部の構造が視認され難く、一層の意匠性の向上を図ることが可能になる他、内部の構造を遮蔽するためのエクステンションを省略して内部構造の簡素化や製造コストの低減を図ることも可能である。 By making the outer peripheral portion 7b of the design surface portion 7 dark in this way, unnecessary light emitted from the light source can be shielded by the outer peripheral portion 7b, thereby preventing irradiation of unnecessary light. By darkening the outer peripheral portion 7b of the surface portion 7, the design of the vehicle lamp 1 can be improved. In addition, by darkening the outer peripheral portion 7b of the design surface portion 7, the internal structure is difficult to be visually recognized when the vehicle lamp 1 is visually recognized from the outside through the cover 3, and it is possible to further improve the design. In addition, it is possible to simplify the internal structure and reduce the manufacturing cost by omitting the extension for shielding the internal structure.
　さらに、ランプハウジング２の溶着用接合部１０がレーザー光の照射により溶融されるため、製造される製品毎にレーザー光の照射角度や照射位置等を変更することにより、同一の製造ラインで種類の異なる製品を製造する所謂段替えを行うことが可能になり、車輌用灯具１の製造コストの低減を図ることができる。また、ランプハウジング２の製造において、製造される製品毎にそれぞれ異なる形状や大きさの熱板を用いる必要がないため、車輌用灯具１の一層の製造コストの低減を図ることができる。 Furthermore, since the welding joint 10 of the lamp housing 2 is melted by the irradiation of the laser beam, by changing the irradiation angle and the irradiation position of the laser beam for each product to be manufactured, different types of products can be manufactured on the same production line. It becomes possible to perform a so-called changeover to manufacture different products, and the manufacturing cost of the vehicle lamp 1 can be reduced. In addition, in the manufacture of the lamp housing 2, it is not necessary to use heat plates of different shapes and sizes for each manufactured product, so that the manufacturing cost of the vehicle lamp 1 can be further reduced.
　さらにまた、レーザーヘッドが固定されミラーを動作させるガルバノレーザー照射装置によってレーザー光の照射が行われる構成にされることにより、高速で溶着用突部６のハウジング側接合面６ａに周回して繰り返しレーザー光を照射することが可能になり、ハウジング側接合面６ａの全体を同時に加熱することができ、溶融作業における作業効率の向上を図ることができる。 Furthermore, since the laser head is fixed and the laser beam is irradiated by the galvano laser irradiation device that operates the mirror, the laser beam is repeatedly circulated on the housing side joint surface 6a of the welding protrusion 6 at high speed. It becomes possible to irradiate light, and the entire housing-side joint surface 6a can be heated at the same time, so that the working efficiency in the melting operation can be improved.
　１…車輌用灯具、２…ランプハウジング、３…カバー、４…本体部、４ａ…内部空間、５…フランジ部、６…溶着用突部、７…意匠面部、８…溶着脚部、１０…溶着用接合部、５０…熱板 DESCRIPTION OF SYMBOLS 1... Vehicle lamp, 2... Lamp housing, 3... Cover, 4... Main body part, 4a... Internal space, 5... Flange part, 6... Welding projection part, 7... Design surface part, 8... Welding leg part, 10... Welding joint, 50 Hot plate

Claims (5)

  1. 　内部空間を有するランプハウジングと前記内部空間を覆うカバーとを備え前記カバーと前記ランプハウジングが溶着によって接合される車輌用灯具であって、
    　前記カバーには外面が車輌の外方を向く意匠面部と前記意匠面部から突出された溶着脚部とが設けられ、
    　前記ランプハウジングには前記溶着脚部と接合される溶着用接合部が設けられ、
    　熱板の加熱によって溶融された前記溶着脚部とレーザー光の照射によって溶融された前記溶着用接合部とが接合される
    　車輌用灯具。     A vehicle lamp comprising a lamp housing having an internal space and a cover covering the internal space, wherein the cover and the lamp housing are joined by welding,
    The cover is provided with a design surface part whose outer surface faces the outside of the vehicle and a welding leg projecting from the design surface part,
    The lamp housing is provided with a welding joint portion that is joined to the welding leg portion,
    A vehicle lamp in which the welding leg portion melted by heating with a hot plate and the welding joint portion melted by laser light irradiation are joined together.
  2. 　前記ランプハウジングに前記内部空間を有する本体部と前記本体部の外周部から外方に張り出されたフランジ部とが設けられ、
    　前記溶着用接合部として前記フランジ部から突出された溶着用突部が設けられた
    　請求項１に記載の車輌用灯具。     The lamp housing is provided with a main body portion having the internal space and a flange portion projecting outward from an outer peripheral portion of the main body portion,
    2. The vehicle lamp according to claim 1, wherein a welding protrusion projecting from the flange portion is provided as the welding joint.
  3. 　前記溶着用突部の幅が前記溶着脚部の幅より大きくされた
    　請求項２に記載の車輌用灯具。     3. The vehicle lamp according to claim 2, wherein the welding projection has a width larger than that of the welding leg.
  4. 　前記溶着脚部が前記熱板と非接触の状態で加熱された
    　請求項１、請求項２又は請求項３に記載の車輌用灯具。     4. The vehicular lamp according to claim 1, wherein the welding leg portion is heated in a non-contact state with the hot plate.
  5. 　内部空間を有するランプハウジングと前記内部空間を覆うカバーとが溶着によって接合される車輌用灯具の製造方法であって、
    　前記カバーにおいて外面が車輌の外方を向く意匠面部から突出された溶着脚部が熱板の加熱によって溶融されると共に前記ランプハウジングにおいてレーザー光の照射によって溶着用接合部が溶融され、
    　前記ランプハウジングと前記カバーの少なくとも一方が他方に近付く方向へ移動されて前記溶着脚部と前記溶着用接合部とが接合される
    　車輌用灯具の製造方法。     A method for manufacturing a vehicle lamp in which a lamp housing having an internal space and a cover covering the internal space are joined by welding,
    The welding leg protruding from the design surface portion of the cover whose outer surface faces the outside of the vehicle is melted by the heating of the hot plate, and the welding joint is melted by the irradiation of the laser beam in the lamp housing,
    A method of manufacturing a vehicle lamp, wherein at least one of the lamp housing and the cover is moved in a direction approaching the other, and the welding leg portion and the welding joint portion are joined.
PCT/JP2022/003041 2021-02-24 2022-01-27 Lamp fixture for vehicle and method for manufacturing lamp fixture for vehicle WO2022181173A1 (en)

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2012001713A (en) * 2010-05-18 2012-01-05 Techno Polymer Co Ltd Thermoplastic resin composition for lamp housings, and molded articles
JP2020107479A (en) * 2018-12-27 2020-07-09 市光工業株式会社 Vehicular lighting fixture

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2012001713A (en) * 2010-05-18 2012-01-05 Techno Polymer Co Ltd Thermoplastic resin composition for lamp housings, and molded articles
JP2020107479A (en) * 2018-12-27 2020-07-09 市光工業株式会社 Vehicular lighting fixture

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