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JP2005339989A - Vehicular lamp and manufacturing method of vehicular lamp - Google Patents

Vehicular lamp and manufacturing method of vehicular lamp Download PDF

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Publication number
JP2005339989A
JP2005339989A JP2004157164A JP2004157164A JP2005339989A JP 2005339989 A JP2005339989 A JP 2005339989A JP 2004157164 A JP2004157164 A JP 2004157164A JP 2004157164 A JP2004157164 A JP 2004157164A JP 2005339989 A JP2005339989 A JP 2005339989A
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Prior art keywords
housing
lens
welding
contact
vehicular lamp
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JP2004157164A
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Japanese (ja)
Inventor
Ryosuke Yasuda
亮介 安田
Fujihiko Sugiyama
富士彦 杉山
Masaru Takiguchi
優 瀧口
Kazuhiro Yamazaki
一廣 山▲崎▼
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Koito Manufacturing Co Ltd
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Koito Manufacturing Co Ltd
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Priority to JP2004157164A priority Critical patent/JP2005339989A/en
Publication of JP2005339989A publication Critical patent/JP2005339989A/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
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/022—Mechanical pre-treatments, e.g. reshaping
    • B29C66/0224—Mechanical pre-treatments, e.g. reshaping with removal of material
    • B29C66/02245—Abrading, e.g. grinding, sanding, sandblasting or scraping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/026—Chemical pre-treatments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/542—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining hollow covers or hollow bottoms to open ends of container bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7316—Surface properties
    • B29C66/73161—Roughness or rugosity
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V17/00—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages
    • F21V17/10—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening
    • F21V17/101—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening permanently, e.g. welding, gluing or riveting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1677—Laser beams making use of an absorber or impact modifier
    • B29C65/1683—Laser beams making use of an absorber or impact modifier coated on the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0072—Roughness, e.g. anti-slip
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/747—Lightning equipment

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Chemical & Material Sciences (AREA)
  • General Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Electromagnetism (AREA)
  • Toxicology (AREA)
  • Securing Globes, Refractors, Reflectors Or The Like (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To allow a lens to be surely brought into contact with a housing in laser welding in jointing the lens to the housing by laser welding. <P>SOLUTION: In this manufacturing method of this vehicular lamp 10, when the housing 30 and the lens 20 covering the front face of the housing are joined to each other by laser welding, welding parts 32 and 22 are formed on the housing and the lens; minute uneven parts 33 and 23 are formed on the welding parts of the housing and/or the lens; the welding parts of the housing and the lens are brought into contact with each other; and the welding parts of the housing and the lens in contact with each other are welded by laser welding. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

本発明は新規な車輌用灯具及び車輌用灯具の製造方法に関する。詳しくは、ハウジングと該ハウジングの前面を覆うレンズとをレーザ溶着によって確実に接合する技術に関する。   The present invention relates to a novel vehicle lamp and a method for manufacturing a vehicle lamp. More specifically, the present invention relates to a technique for reliably joining a housing and a lens covering the front surface of the housing by laser welding.

車輌用灯具、例えば、自動車用灯具の製造において、ハウジングにその前面開口を覆うようにレンズを取り付ける工程が必要である。   In the manufacture of a vehicular lamp, for example, an automotive lamp, a process of attaching a lens to the housing so as to cover the front opening is required.

従来にあっては、レンズとハウジングとの間の取付には、レンズの周縁部にシール脚を突設し、ハウジングには上記シール脚を受け入れる溝を形成し、レンズのシール脚をハウジングの溝にシール材或いは接着材を介して受け入れる方法が一般的に採用されていたが、この取付方法にあっては、シール脚や溝はレンズやハウジングの周縁部からさらに外方へと突出した部分に設けられるため、レンズを前方から眺めたときに、その周縁部に比較的大きな面積を占める光を通さない部分、すなわち、暗い部分が出来てしまい、全体の大きさの割には発光面積が小さくなると言う問題があった。   Conventionally, for mounting between the lens and the housing, a seal leg protrudes from the periphery of the lens, a groove for receiving the seal leg is formed in the housing, and the lens seal leg is inserted into the groove of the housing. However, in this mounting method, the seal legs and grooves are located on the part that protrudes further outward from the periphery of the lens and housing. Therefore, when the lens is viewed from the front, a portion that does not allow light to occupy a relatively large area at the peripheral portion, that is, a dark portion is formed, and the light emitting area is small for the overall size. There was a problem to say.

そこで、レンズのシール脚をハウジングの接合面に直接接合する方法が考えられた。レンズのシール脚をハウジングに直接接合するようにすれば、接合代はほんの僅かの幅があれば良く、レンズ周縁部の暗く見える部分は極めて狭い幅で足りることになる。そして、この直接接合する手段としては、熱板溶着、振動溶着等が一般的に採用されていた。これらの手段にあっては、レンズとハウジングとの接合部に互いの材料の溶融した部分が混合した状態で冷却固化されることによって接合されるのであるが、余分な溶融材料が接合箇所から脇にはみ出して、これが前方からレンズを通して視認されて外観を損ねるという問題がある。   Therefore, a method of directly joining the lens seal leg to the joint surface of the housing has been considered. If the lens seal leg is joined directly to the housing, the joining margin need only be a small width, and the portion of the lens peripheral edge that appears dark will suffice. In general, hot plate welding, vibration welding, or the like has been employed as the means for direct bonding. In these means, the molten portion of the material is mixed and cooled and solidified in a mixed state at the joint portion between the lens and the housing. There is a problem in that it protrudes and is visually recognized through the lens from the front and impairs the appearance.

また、形状の制限がある（傾斜角度に制限がある；振動溶着では振動する方向には略平坦でなければならない、熱板溶着では熱板を押し当てる方向に対して極端な傾斜はできない、等）ので、昨今の立体的なデザインニーズに対応できない。   In addition, there are restrictions on the shape (inclination angle is limited; in vibration welding, the direction of vibration must be substantially flat, in hot plate welding, there is no extreme inclination with respect to the direction in which the hot plate is pressed, etc. Therefore, it cannot respond to the recent three-dimensional design needs.

さらに、レンズとハウジングをレーザー溶着により接合する方法がある。レーザー溶着にあっては、レーザー出力と接合部におけるスポット径並びに走査スピードを制御することにより材料の溶融状態、すなわち、接合部における照射エネルギーを一定にをコントロールすることが出来るので、溶融のしすぎによる溶融材料のはみ出しを解決でき、複雑な形状にも対応できる。レーザーを、レンズを透過させてハウジングを照射することにより、ハウジングを加熱して溶融させるとともに、レンズにも熱伝導させて溶融させ、両者が相溶して融着される。   Further, there is a method of joining the lens and the housing by laser welding. In laser welding, by controlling the laser output, the spot diameter at the joint, and the scanning speed, it is possible to control the molten state of the material, that is, the irradiation energy at the joint to be constant, so it is too melted. Can solve the overflow of molten material due to, and can cope with complicated shapes. By irradiating the housing with the laser passing through the lens, the housing is heated and melted, and the lens is also thermally conducted and melted.

ところで、レーザー溶着にあっては、レンズの溶着部とハウジングの溶着部とが確実に接触していないと接合不良を起こす。   By the way, in laser welding, if the welded portion of the lens and the welded portion of the housing are not in reliable contact, poor bonding occurs.

しかしながら、車輌用灯具のレンズとハウジングは樹脂成形品であり、成形後のソリや撓みなどの影響から、実際には設計通りの形状を出すことは困難である。そのため、レンズとハウジングとを全周に亘って確実に接触させることは困難である。そして、レンズとハウジングとが確実に接触していないと、レーザーによってハウジングに与えられた熱がレンズに伝達せず、溶着が不能になる。   However, the lens and housing of the vehicular lamp are resin molded products, and it is difficult to actually obtain the shape as designed due to the influence of warpage and bending after molding. Therefore, it is difficult to reliably contact the lens and the housing over the entire circumference. If the lens and the housing are not in contact with each other, heat applied to the housing by the laser is not transmitted to the lens, and welding becomes impossible.

そこで、本発明は、レンズとハウジングとをレーザー溶着によって接合するに際して、レーザ溶着時にレンズとハウジングとが確実に接触しているようにすることを課題とする。   Accordingly, an object of the present invention is to ensure that the lens and the housing are in contact with each other at the time of laser welding when the lens and the housing are joined by laser welding.

本発明車輌用灯具の製造方法は、上記した課題を解決するために、ハウジング及びレンズは共に溶着部を備えており、上記ハウジング及び／又はレンズの溶着部には微細な凹凸が形成されており、上記ハウジング及びレンズの溶着部を互いに接触させる工程と、互いに接触したハウジング及びレンズの溶着部をレーザ溶着する工程を備えたものである。   In the vehicle lamp manufacturing method of the present invention, in order to solve the above-described problems, both the housing and the lens are provided with a welded portion, and fine unevenness is formed on the welded portion of the housing and / or the lens. And a step of bringing the welded portion of the housing and the lens into contact with each other and a step of laser welding the welded portion of the housing and the lens in contact with each other.

また、本発明車輌用灯具は、上記した課題を解決するために、ハウジング及びレンズは互いに溶着される溶着部を備え、少なくとも一方に微細な凹凸が形成された上記溶着部同士が互いに接触された状態でレーザ溶着によって接合されて成るものである。   Further, in order to solve the above-described problems, the vehicle lamp according to the present invention includes a welded portion in which the housing and the lens are welded to each other, and at least one of the welded portions in which fine irregularities are formed is in contact with each other In this state, they are joined by laser welding.

従って、本発明にあっては、ハウジングの溶着部とレンズの溶着部とを接触させるとき、微細な凹凸が潰れることによって、ハウジングの溶着部とレンズの溶着部との間に隙間が無くなり、全周に亘ってハウジングの溶着部とレンズの溶着部とが確実に接触する。   Therefore, in the present invention, when the welded part of the housing and the welded part of the lens are brought into contact with each other, a gap is eliminated between the welded part of the housing and the welded part of the lens by collapsing the fine irregularities. The welded part of the housing and the welded part of the lens are reliably in contact with each other over the circumference.

本発明車輌用灯具の製造方法は、ハウジングと該ハウジングの前面を覆うレンズとがレーザ溶着によって結合される車輌用灯具の製造方法であって、上記ハウジング及びレンズは共に溶着部を備えており、上記ハウジング及び／又はレンズの溶着部には微細な凹凸が形成されており、上記ハウジング及びレンズの溶着部を互いに接触させる工程と、互いに接触したハウジング及びレンズの溶着部をレーザ溶着する工程を備えたことを特徴とする。   The vehicle lamp manufacturing method of the present invention is a vehicle lamp manufacturing method in which a housing and a lens covering the front surface of the housing are coupled by laser welding, both the housing and the lens including a welded portion, The housing and / or lens weld has fine irregularities, and includes a step of bringing the housing and lens weld into contact with each other, and a step of laser welding the housing and lens weld in contact with each other. It is characterized by that.

また、本発明車輌用灯具は、ハウジングと該ハウジングにその前面を覆うように取り付けられたレンズを備えた車輌用灯具であって、上記ハウジング及びレンズは互いに溶着される溶着部を備え、少なくとも一方に微細な凹凸が形成された上記溶着部同士が互いに接触された状態でレーザ溶着によって接合されて成ることを特徴とする。   The vehicular lamp of the present invention is a vehicular lamp including a housing and a lens attached to the housing so as to cover the front surface of the vehicular lamp, wherein the housing and the lens include a welded portion to be welded to each other. It is characterized in that the welded portions having fine irregularities formed thereon are joined by laser welding while being in contact with each other.

従って、本発明にあっては、ハウジングの溶着部とレンズの溶着部とを接触させるとき、微細な凹凸が潰れることによって、ハウジングの溶着部とレンズの溶着部との間に隙間が無くなり、全周に亘ってハウジングの溶着部とレンズの溶着部とが確実に接触する。   Therefore, in the present invention, when the welded part of the housing and the welded part of the lens are brought into contact with each other, a gap is eliminated between the welded part of the housing and the welded part of the lens by collapsing the fine irregularities. The welded part of the housing and the welded part of the lens are reliably in contact with each other over the circumference.

すなわち、ハウジングの溶着部とレンズの溶着部とを全周に亘って接触させることは、成形後の撓みや変形によって、難しいが、２つの溶着部を接触させるとき、先に接触し始める部分と後で接触する部分とがあるが、先に接触を始めた部分では溶着部に形成された微細な凹凸が先に潰れ始め、その分、多く（高さ方向のほとんどの部分）が潰れ、後で接触した部分では微細な凹凸が僅かに（高さ方向の僅かの部分）潰れ、その結果、全周に亘って、間隙が生じている部分が無くなる。   That is, it is difficult to contact the welded portion of the housing and the welded portion of the lens over the entire circumference due to bending and deformation after molding, but when the two welded portions are brought into contact with each other, There is a part that comes in contact later, but in the part that started contact first, the fine irregularities formed in the welded part started to collapse first, and much (most part in the height direction) collapsed, and later In the contacted portion, the fine irregularities are slightly crushed (a small portion in the height direction), and as a result, there is no portion having a gap over the entire circumference.

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最良の形態について添付図面を参照して説明する。   The best mode for carrying out the vehicular lamp and the vehicular lamp manufacturing method of the present invention will be described below with reference to the accompanying drawings.

図１に車輌用灯具の一例を示す。   FIG. 1 shows an example of a vehicle lamp.

車輌用灯具１０はレンズ２０とハウジング３０を備え、ハウジング３０は前面で開口した凹部３１を有し、開口縁の全周３２が溶着部としての溶着面とされる。このようなハウジング３０はレーザー吸収性の良好なプラスチック、例えば、ＡＳＡ（アクリロニトリルスチレンアクリレート）の射出成形によって形成されている。   The vehicular lamp 10 includes a lens 20 and a housing 30, and the housing 30 has a recess 31 that is open on the front surface, and the entire periphery 32 of the opening edge serves as a welding surface as a welding portion. Such a housing 30 is formed by injection molding of a plastic having good laser absorption, for example, ASA (acrylonitrile styrene acrylate).

レンズ２０は周縁部から後方へ向かって突出した溶着脚２１を有しており、該溶着脚２１の後面２２が溶着部としての溶着面とされている。このようなレンズ２０はレーザー透過性のあるプラスチック、例えば、アクリル樹脂の射出成形によって形成されている。   The lens 20 has a welding leg 21 protruding rearward from the peripheral edge portion, and a rear surface 22 of the welding leg 21 is a welding surface as a welding portion. Such a lens 20 is formed by injection molding of a laser transmissive plastic, for example, an acrylic resin.

上記レンズ２０はその溶着面２２がハウジング３０の溶着面３２にレーザー溶着によって接合され、そして、ハウジング３０に光源バルブ４０が支持されて、車輌用灯具１０が形成される。   The lens 20 has a welding surface 22 joined to a welding surface 32 of the housing 30 by laser welding, and a light source bulb 40 is supported on the housing 30 to form the vehicular lamp 10.

上記レンズ２０の溶着面２２は上記ハウジング３０の溶着面３２と全周に亘って接触するように設計されている。しかしながら、レンズ２０及びハウジング３０は上記したように樹脂成形品であり、成形後のソリや撓みなどの影響から、実際には設計通りの形状を出すことは困難である。そのため、レンズ２０の溶着面２２とハウジング３０の溶着面３２とを単に突き合わせただけでは、互いに接触することができない部分が生じてしまうことがある。   The welding surface 22 of the lens 20 is designed to be in contact with the welding surface 32 of the housing 30 over the entire circumference. However, the lens 20 and the housing 30 are resin molded products as described above, and it is actually difficult to obtain the shape as designed due to the influence of warpage and bending after molding. Therefore, if the welding surface 22 of the lens 20 and the welding surface 32 of the housing 30 are merely brought into contact with each other, there may be a portion that cannot be brought into contact with each other.

図２は接合前のハウジングとレンズの溶着部を拡大して示す概略断面図である。図２の引出部に示すように、ハウジング３０の溶着面３２とレンズ２０の溶着面２２にはそれぞれ微細な凹凸２３、２３、・・・、３３、３３、・・・が形成されている。これら凹凸２３、２３、・・・、３３、３３、・・・の高さ（深さ）は１０μｍ〜５００μｍの範囲のものが好ましい。なお、図２では、凹凸を実際の寸法で示すことは不可能であるので、誇張して示している。   FIG. 2 is an enlarged schematic cross-sectional view showing a welded portion between the housing and the lens before joining. As shown in the drawing portion of FIG. 2, fine irregularities 23, 23,..., 33, 33, ... are formed on the welding surface 32 of the housing 30 and the welding surface 22 of the lens 20. The height (depth) of these irregularities 23, 23, ..., 33, 33, ... is preferably in the range of 10 µm to 500 µm. In FIG. 2, since it is impossible to show the unevenness with actual dimensions, it is exaggerated.

上記した凹凸２３、２３、・・・、３３、３３、・・・はレンズ２０及びハウジング３０の成形用金型の当該箇所、すなわち、溶着面２２、３２が転写される面にエッチング処理、サンドブラスト処理等を行うことによって、形成可能である。   The above-described irregularities 23, 23,..., 33, 33,... Are etched and sandblasted on the portions of the mold for molding the lens 20 and the housing 30, that is, the surfaces to which the welding surfaces 22 and 32 are transferred. It can be formed by processing or the like.

そして、レンズ２０とハウジング３０との接合工程にあっては、まず、レンズ２０の溶着面２２とハウジング３０の溶着面３２とを接触させる工程がある。なお、単に、レンズ２０の溶着面２２とハウジング３０の溶着面３２とを突き合わせただけでは、レンズ２０、ハウジング３０の双方或いは一方の成形後のソリや撓みによって全周に亘って接触するとは限らない。そこで、レンズ２０、ハウジング３０の一方又は双方を相手の方に向かって押圧する。この押圧力がそれぞれの微細な凹凸２３、２３、・・・、３３、３３、・・・に作用して、これら微細な凹凸２３、２３、・・・、３３、３３、・・・が押し潰され、その潰れカス２４、２４、・・・、３４、３４、・・・が２つの溶着面２２と３２との間を埋め尽くし、これによって、２つの溶着面２２、３２が全周に亘って接触する（図３参照）。なお、上記したように、１０μｍ〜５００μｍの高さの凹凸を形成した場合、これら凹凸が押し潰されていない状態で２つの溶着面２２、３２の間に生じた０．５ｍｍ以下の間隙を埋めることが出来る。   In the joining process of the lens 20 and the housing 30, first, there is a process of bringing the welding surface 22 of the lens 20 and the welding surface 32 of the housing 30 into contact with each other. It should be noted that simply contacting the welding surface 22 of the lens 20 and the welding surface 32 of the housing 30 does not always contact the entire circumference due to warping or bending after molding of either the lens 20 or the housing 30 or one of them. Absent. Therefore, one or both of the lens 20 and the housing 30 are pressed toward the other party. This pressing force acts on each fine unevenness 23, 23, ..., 33, 33, ..., and these fine unevennesses 23, 23, ..., 33, 33, ... are pressed. .., 34, 34,... Fills the space between the two welding surfaces 22 and 32, so that the two welding surfaces 22 and 32 are arranged around the entire circumference. (See FIG. 3). As described above, when irregularities having a height of 10 μm to 500 μm are formed, a gap of 0.5 mm or less generated between the two welding surfaces 22 and 32 is filled with the irregularities not being crushed. I can do it.

レンズ２０とハウジング３０の溶着面２２、３２同士を接触させたら、レーザヘッド５０をレンズ２０の前方に位置させ、レーザ光５１をレンズ２０の溶着脚２１を通してレンズ２０の溶着面２２とハウジング３０の溶着面３２とが接触している部分に照射する（図４参照）。これによって、２つの溶着面２２、３２の間を埋めている潰れカス２４、２４、・・・、３４、３４、・・・がレーザ光５１を吸収して加熱、溶融され、さらに、その熱がレンズ２０の溶着面２２及びハウジング３０の溶着面３２に伝導し、これら溶着面２２、３２も上記潰れカス、２４、２４、・・・、３４、３４、・・・と共に加熱、溶融され、相溶状態となり、そして、これが冷却されて固化されることによって、レンズ２０とハウジング３０とが互いの溶着面２２、３２によって強固に接合される。   When the welding surfaces 22 and 32 of the lens 20 and the housing 30 are brought into contact with each other, the laser head 50 is positioned in front of the lens 20, and the laser light 51 passes through the welding legs 21 of the lens 20 and the welding surface 22 of the lens 20 and the housing 30. It irradiates the part which the welding surface 32 is contacting (refer FIG. 4). .., 34, 34,... Filling the space between the two welding surfaces 22, 32 absorbs the laser beam 51 and is heated and melted. Is transmitted to the welding surface 22 of the lens 20 and the welding surface 32 of the housing 30, and these welding surfaces 22 and 32 are also heated and melted together with the above-mentioned crushing residue 24, 24,..., 34, 34,. The lens 20 and the housing 30 are firmly bonded to each other by the welding surfaces 22 and 32 by being in a compatible state and being cooled and solidified.

なお、レーザ光の照射は、上記したように、レンズ２０の前面側から行うものに限らず、例えば、レンズ２０の溶着脚２１の側面から行っても良い。   Note that, as described above, the laser light irradiation is not limited to being performed from the front surface side of the lens 20, but may be performed from the side surface of the welding leg 21 of the lens 20, for example.

また、上記した実施の形態では、レンズ２０の溶着面２２とハウジング３０の溶着面３２の双方に微細な凹凸を形成した例を示したが、微細な凹凸はレンズ２０の溶着面２２、ハウジング３０の溶着面３２の何れか一方にのみ形成されていても良い。   In the above-described embodiment, an example in which fine irregularities are formed on both the welding surface 22 of the lens 20 and the welding surface 32 of the housing 30 has been described. However, the fine irregularities are the welding surface 22 of the lens 20 and the housing 30. It may be formed only on one of the welding surfaces 32.

その他、上記した実施の形態において示した各部の具体的形状及び構造は、何れも本発明を実施するに際して行う具体化のほんの一例を示したものに過ぎず、これらによって本発明の技術的範囲が限定的に解釈されることがあってはならないものである。   In addition, the specific shapes and structures of the respective parts shown in the above-described embodiments are merely examples of implementations in carrying out the present invention, and the technical scope of the present invention is thereby limited. It should not be interpreted in a limited way.

車輌用灯具、特に大型の車輌用灯具におけるハウジングとレンズとの接合に適用して、外観を損ねること無しに、確実な接合を行うことが出来る。   By applying it to the joining of a housing and a lens in a vehicular lamp, particularly a large vehicular lamp, a reliable joining can be performed without impairing the appearance.

車輌用灯具の実施の形態を示す概略縦断面図である。It is a schematic longitudinal cross-sectional view which shows embodiment of the vehicle lamp. 接合前のハウジングとレンズの要部を拡大して示す概略断面図である。It is a schematic sectional drawing which expands and shows the principal part of the housing and lens before joining. ハウジング及びレンズの溶着面を接触させる工程を示す要部の概略拡大断面図である。It is a general | schematic expanded sectional view of the principal part which shows the process of contacting the welding surface of a housing and a lens. レーザ溶着工程を示す要部の概略拡大断面図である。It is a general | schematic expanded sectional view of the principal part which shows a laser welding process.

符号の説明Explanation of symbols

１０…車輌用灯具、２０…レンズ、２２…溶着面、２３…微細な凹凸、３０…ハウジング、３２…溶着面、３３…微細な凹凸   DESCRIPTION OF SYMBOLS 10 ... Vehicle lamp, 20 ... Lens, 22 ... Welding surface, 23 ... Fine unevenness, 30 ... Housing, 32 ... Welding surface, 33 ... Fine unevenness

Claims (2)

ハウジングと該ハウジングの前面を覆うレンズとがレーザ溶着によって結合される車輌用灯具の製造方法であって、
上記ハウジング及びレンズは共に溶着部を備えており、
上記ハウジング及び／又はレンズの溶着部には微細な凹凸が形成されており、
上記ハウジング及びレンズの溶着部を互いに接触させる工程と、
互いに接触したハウジング及びレンズの溶着部をレーザ溶着する工程を備えた
ことを特徴とする車輌用灯具の製造方法。 A vehicle lamp manufacturing method in which a housing and a lens covering the front surface of the housing are coupled by laser welding,
Both the housing and the lens have a welded portion,
Fine irregularities are formed on the welded portion of the housing and / or lens,
Contacting the welded portion of the housing and lens with each other;
A method for manufacturing a vehicular lamp, comprising a step of laser welding a welded portion of a housing and a lens that are in contact with each other. ハウジングと該ハウジングにその前面を覆うように取り付けられたレンズを備えた車輌用灯具であって、
上記ハウジング及びレンズは互いに溶着される溶着部を備え、
少なくとも一方に微細な凹凸が形成された上記溶着部同士が互いに接触された状態でレーザ溶着によって接合されて成る
ことを特徴とする車輌用灯具。
A vehicle lamp comprising a housing and a lens attached to the housing so as to cover the front surface thereof,
The housing and the lens include a welded portion that is welded to each other,
A vehicular lamp characterized by being formed by laser welding in which the welds having fine irregularities formed on at least one of them are in contact with each other.
JP2004157164A 2004-05-27 2004-05-27 Vehicular lamp and manufacturing method of vehicular lamp Pending JP2005339989A (en)

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WO2013136955A1 (en) * 2012-03-14 2013-09-19 アイシン精機株式会社 Wall body fastening part structure and method for manufacturing vehicle component
JP2013196845A (en) * 2012-03-16 2013-09-30 Stanley Electric Co Ltd Vehicle lamp, and manufacturing method of vehicle lamp
US9163800B2 (en) 2012-03-16 2015-10-20 Stanley Electric Co., Ltd. Outer casing for vehicle lamp, vehicle lamp and manufacturing method for the same
WO2020110510A1 (en) * 2018-11-30 2020-06-04 オムロン株式会社 Lens unit, method for manufacturing lens unit, object detection device
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102063914A (en) * 2009-11-11 2011-05-18 日立视听媒体股份有限公司 Optical component laser-welded structure and optical pickup manufacturing method
JP2011103159A (en) * 2009-11-11 2011-05-26 Hitachi Media Electoronics Co Ltd Laser-welding structure of optical component and method for manufacturing optical pickup
CN102063914B (en) * 2009-11-11 2014-03-12 日立视听媒体股份有限公司 Optical component laser-welded structure and optical pickup manufacturing method
WO2013136955A1 (en) * 2012-03-14 2013-09-19 アイシン精機株式会社 Wall body fastening part structure and method for manufacturing vehicle component
JP2013189822A (en) * 2012-03-14 2013-09-26 Aisin Kiko Co Ltd Wall body fastening part structure and manufacturing method of vehicle component
JP2013196845A (en) * 2012-03-16 2013-09-30 Stanley Electric Co Ltd Vehicle lamp, and manufacturing method of vehicle lamp
US9163800B2 (en) 2012-03-16 2015-10-20 Stanley Electric Co., Ltd. Outer casing for vehicle lamp, vehicle lamp and manufacturing method for the same
WO2020110510A1 (en) * 2018-11-30 2020-06-04 オムロン株式会社 Lens unit, method for manufacturing lens unit, object detection device
JP2020086375A (en) * 2018-11-30 2020-06-04 オムロン株式会社 Lens unit, method of manufacturing lens unit, object detection apparatus
JP7206860B2 (en) 2018-11-30 2023-01-18 オムロン株式会社 Lens unit, object detection device
CN115398146A (en) * 2020-04-03 2022-11-25 海拉有限双合股份公司 Lighting device and method for connecting a lighting device

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