CN1320787A - 车灯单元及其制造方法 - Google Patents

车灯单元及其制造方法 Download PDF

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Publication number
CN1320787A
CN1320787A CN01119202A CN01119202A CN1320787A CN 1320787 A CN1320787 A CN 1320787A CN 01119202 A CN01119202 A CN 01119202A CN 01119202 A CN01119202 A CN 01119202A CN 1320787 A CN1320787 A CN 1320787A
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China
Prior art keywords
sealing strip
lamp body
headlight lens
laser beam
face
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CN01119202A
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CN1157553C (zh
Inventor
秋山一夫
杉山富士彦
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Koito Manufacturing Co Ltd
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Koito Manufacturing Co Ltd
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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
    • B29C65/1654—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
    • B29C65/1629—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
    • 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
    • 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
    • B29C65/1687—Laser beams making use of light guides
    • B29C65/169—Laser beams making use of light guides being a part of the joined 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • 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
    • B29C66/112—Single lapped joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/05—Particular design of joint configurations
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    • B29C66/12449—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue being asymmetric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/05—Particular design of joint configurations
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    • B29C66/124—Tongue and groove joints
    • B29C66/1246—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove
    • B29C66/12463—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove being tapered
    • B29C66/12464—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove being tapered being V-shaped
    • 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
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove joints
    • B29C66/1246—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove
    • B29C66/12469—Tongue and groove joints characterised by the female part, i.e. the part comprising the groove being asymmetric
    • 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
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B29C66/1312—Single flange to flange joints, the parts to be joined being rigid
    • 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
    • B29C66/301—Three-dimensional joints, i.e. the joined area being substantially non-flat
    • 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
    • B29C66/50—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
    • B29C66/65—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 with a relative motion between the article and the welding tool
    • B29C66/652—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 with a relative motion between the article and the welding tool moving the welding tool around the fixed 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
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    • 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
    • B29C66/733—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
    • B29C66/7334—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being glossy or matt, reflective or refractive
    • B29C66/73343—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being glossy or matt, reflective or refractive at least one of the parts to be joined being matt or refractive
    • 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
    • B29C66/733—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
    • B29C66/7336—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 optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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Abstract

车灯,可增强粘接强度和改善粘接表面周围的外观质量,还避免了出现粘接缺陷。前灯玻璃的密封边端面和灯体的接受表面通过激光束焊接被粘接。所述的端面形成在按照相对于粘接方向呈预定角度向外弯曲并延伸的密封边的端部上。激光束由基本上垂直于所述的端面的方向通过所述的端部照射到接受表面上。激光束的总的穿透距离变短,使得辐射能量充足。在通过对前灯玻璃加压的方式将压力施加到密封边的基端部分时,使得压力在宽度方向均匀。

Description

车灯单元及其制造方法
本发明涉及一种车灯单元及其制造方法，在其中，前灯玻璃和灯体是直接粘接在一起。
按照常规，已知有两种类型的用于粘接车灯单元的前灯玻璃和灯体的方法，即经由密封器件的间接粘接法(例如热溶密封法)和通过使两个器件直接紧靠(例如加热板焊接法、振动焊接法、超声焊接法等)的直接粘接法。
做为一种直接粘接法，激光束焊接在其他一些领域中已是公知的。这样的一种方法也适合于粘接前灯玻璃和灯体。一种这样的工艺方法将参照图8加以描述(还可以阅读具有共同受让人的待审美国专利申请09/548361)。
参照图8，形成一沿前灯玻璃2的外周边在朝外的方向上延伸的密封边2a。沿灯体4的前端开口部分形成一接受表面4a。灯体4被置于接受平台102上。前灯玻璃2被设置在灯体4上，所采用的方式使得密封边2a的端面2b紧贴接受表面4a。前灯玻璃2进一步覆盖有一块用于将它压在灯体4上的透明压板104。在上述状态下，一激光束L由前灯玻璃2上方的一个位置穿过透明压板104和密封边2a照射到接受表面4a上。结果，接受表面4a被激光束L的辐射能量加热熔化以便于与业已被加热溶化的密封边2a的端面2b融合。于是，借助于在前灯玻璃2的整个长度范围内沿密封边2a扫描激光束L，前灯玻璃2和灯体4彼此被粘合在一起。
使用上述激光焊接方法使得可以将前灯玻璃2和灯体4粘合在一起而不会在相应的焊接表面上产生毛刺，结果改善了粘接表面周边部分周围外观的质量。然而，这种焊接方法还可能导致某些缺陷。
即在激光束焊接方法中，激光束L穿透透明压板104和密封边2a，其与穿透距离成正比地减少了激光束L的辐射能量，(穿透距离通过将密封边2a的全长与透明压板104的厚度相加求出)。此外，由于必须避开激光束L的光程，所以不得不将前灯玻璃2在从密封边2a正上方位置移出的一位点上加压。因此，密封边2a的端面2b和接受表面4a在宽度方向上不能以均匀的压力贴合。结果，不能在粘接表面的整个宽度范围内保证所需要的粘接强度。
发明的概述
本发明鉴于前述情况作出的。因此，本发明的一个任务是提供一种车灯单元及其制造方法，在其中，前灯玻璃和灯体是直接粘合在一起，以便于改善外观质量和增强前灯玻璃和灯体之间的粘接强度。
前述任务是由本发明通过使用激光束焊接做为将前灯玻璃和灯体粘合在一起的方法和恰当地确定粘接表面周边的结构实现的。
本发明具有直接粘合在一起的前灯玻璃和灯体的车灯单元的特征在于在朝外的方向上延伸的密封边形成在前灯玻璃的外周边上，紧贴密封边的端面的接受表面形成在灯体上，密封边的端面和接受表面通过激光束焊接直接粘合在一起，以及凸出出来以便于将从与灯的基准轴呈一个角度的方向进入的激光束引导至所述的端面的激光束接受面形成在密封边的外侧表面上。
“激光束焊接”这一个术语表示一种焊接方法，根据这种焊接方法，允许激光束穿透的激光束透射器件紧贴不允许激光束穿透的激光束非透射器件，两器件在朝外的方向上受压，激光束通过激光束透射器件照射到两器件的邻接面上，以便于加热激光束非透射器件。结果两器件融合在一起。，对于用于激光束焊接的激光器没有具体的限制，例如，半导体激光器、YAG激光器或其他类似的激光器都可以使用。
对于形成灯体的材料没有具体的限制，只要它不允许激光束透射并能被激光束辐射加热溶化。关于有效的激光束焊接，最好灯体是用其中加入了辅助材料，例如碳黑，以便增强灯体的吸收激光束的能力的黑色材料制成的。
此外，对于用做前灯玻璃的材料也无具体的限制，只要它能使可见光和激光穿透和能使它溶化并且与已溶化的灯体相混合。
对于激光束接受面的结构也没有具体的限制，只要能将激光束辐射从与被粘接表面成一角度的方向引导至密封边的端面。
按照前述的结构，本发明的车灯单元的前灯玻璃和灯体利用激光焊接被直接焊接在一起，结果使得形成在前灯玻璃上的密封边端面被粘接在形成在灯体上的接受表面上。速使得粘接不会在相应的粘接面上产生毛刺，从而改善了粘接表面周围的外观质量。
本发明的车灯单元具有一个投射激光束接受面，用于将照射到在朝外的方向上延伸的密封边外表面的激光束从与所述的被粘接表面成一角度的方向引导至密封边的端面上。这可提供了下述有益的效果。
在粘接操作过程中，激光束的穿透距离相当于密封边的激光接受表面到端面的距离。这一距离可以变得比通过激光穿透透明压板和密封边完成粘接的情况短得多。结果，可以使用足够的辐射能量完成激光束粘接。
激光束从一个与被粘接表面成一个角度的方向照射。这使得可以将一个压力施加到密封边的底端部分对前灯玻璃加压。可以使密封边部分的端面和接受表面在相对于其宽度方向的均匀的压力下彼此靠紧。这样，就可以在被粘接表面的整个宽度范围内获得所需要的粘接强度。
在具有根据本发明的具有直接粘合在一起的前灯玻璃和灯体的车灯单元中，前灯玻璃和灯体之间的粘接强度获得充分增强，同时还改善了粘接表面周围的外观质量。
由于采用了使得密封边的端部按一个预先确定的相对于粘接表面的角度向外周边弯曲的车灯单元结构，所以可以获得下述有益的效果。
即使是在密封边的端面或接受表面由于不够光滑而具有波纹状不规则性使得在它们之间产生间隙的情况下，由于被粘接的表面是倾斜的，施加在待粘接的那些部件上的压力引起它们之间的滑移。这种滑移作用将在这两个器件之间区域中产生的间隙消除以便使它们在被粘接表面的整个长度范围内紧贴。于是，粘接失败被防止。端部的粘接角度没有被限制为一具体数值，无论大还是小，只要小于90°。
在这种情况下，可以为灯体的接受表面设置在沿前灯玻璃的密封边的端部的外侧表面朝外的方向上突起的外肋，结果使得所述的外肋紧靠密封边。这使得可以防止在粘接操作过程中由于作用在被粘接表面上的压力在密封边的端面和接受表面之间产生不必要的滑移。
在以上情况中，可以进一步为灯体的接受表面设置在沿前灯玻璃的密封边的端部的内侧表面朝外的方向上突起的内肋。即使从基本上与密封边的端面垂直的方向上发射的激光束的方向稍有偏移，激光束仍然能够照射到所述内肋的外侧表面，以便于将内肋适当地加热溶化。内肋的外侧表面密封边的内侧表面可以被粘接，以确定一第二粘接表面。这使得可以进一步加强前灯玻璃和灯体之间的粘接强度。
附图简要说明
图1是根据本发明的第一个实施例的车灯单元的侧面剖视图，图中的车灯顶部朝上。
图2是详细显示图1中所示的部分Ⅱ的视图。
图3是显示车灯单元和在该实施例中用于完成激光束焊接的焊接机器人的透视图。
图4是显示图1的实施例的第一改进例子的类似于图2的视图。
图5是显示图1的实施例的第二改进例子的类似于图2的视图。
图6是显示图1的实施例的第三改进例子的类似于图2的视图。
图7是显示根据本发明的第二个实施例构成的车灯单元的基本部分的类似于图2的视图。
图8是说明在利用激光焊接粘接前灯玻璃和灯体的情况下常规使用的粘接方法的类似于图2的视图。
一些优选实施例的说明
以下将参照附图描述本发明的一些优选的实施例。
以下将描述本发明的第一个实施例。
图1是根据本发明的第一个实施例的车灯单元的侧面剖视图，图中的车灯顶部朝上。图2是详细显示图1中所示的部分Ⅱ的视图。
如这些视图所示，车灯单元10被实施用做信号灯，例如尾灯。车灯单元10包括灯体14，光源灯泡12安装于灯的基准轴线上，灯泡的延伸方向在图中是垂直的(在安装在车辆上时处在相对于车灯单元的纵向)，而前灯玻璃16直接粘接在灯体14上。
前灯玻璃16是用透明热塑性树脂材料，例如PMMA或PC制造的。前灯玻璃16的外周边边缘部分带有在整个长度范围内朝下延伸的密封边16a。密封边16a的主体部分16b垂直延伸，而端部16c向下倾斜延伸以便按照相对于车灯的基准轴线(即图中垂直方向)45°角朝向外周边弯曲。因此，密封边16的端面(下端表面)16d和端部16c的上倾斜面16j被制作成相对于垂直轴线呈45°角的倾斜面。上倾斜面16j被制作成激光束接受面。形成端部16c的外侧表面16e以构成垂直面。
灯体14是用不透明的热塑性树脂材料，例如AAS或ABS制造的。它带有在其前端开口垂直延伸的边缘翼部14a。类似于密封边16的端面16d，边缘翼部14a的端面(上端表面)14b被制作成相对于基准轴线呈45°角的向下倾斜的平面。端面14b构成密封边16a的端面16d紧贴的接受面。接受面14b带有沿密封边16a的端部16c的外侧表面16e垂直凸出的外肋14c。
通过将密封边16a的端面16d激光束焊接到接受表面14b上的方式将前灯玻璃16粘接到灯体14上。
图3是显示车灯单元10和用于激光束焊接的焊接机器人110的透视图。
参照该图，利用焊接机器人110，使车灯单元10顶部朝上，进行激光束焊接。
焊接机器人110是由其上安装有激光头112的机器人主体(未示出)构成的。这个激光头112带有一根光缆114，该光缆114包括有一根光纤和具有内装电容透镜(capacitorlens)的发射喷口(emission nozzle)116。由一个激光振荡器(未示出)产生的激光束以汇聚光束的形式通过光缆114从发射喷口116被发射。从发射喷口116发射的激光束用于在大约60mm的焦距形成直径大约1.5mm的激光点。所述的激光振荡器是由一个输出功率为15至100瓦、波长为0.8至1.5m的半导体激光器构成。
激光束焊接是按以下方式完成的。
如图2中所示，灯体14被放置在一个接受夹具102上，前灯玻璃16被安装在灯体14上，其安装方式使得密封边16a的端面16d紧贴接受表面14b。前灯玻璃16进一步用一个透明压板104覆盖，以便于通过向密封边16a的基部施加压力的方式通过透明压力板104将前灯玻璃2向下压在灯体4上。
激光头112在前灯玻璃16的密封边16a的上方倾斜定位，以便于按照倾斜向下45°角的方向从发射喷口116发射激光束。激光束L朝向密封边16a的端部16c的激光束接受面16i被发射，以便于穿透端部16c并照射到灯体14的接受面14b上。接受面14b被激光束L的辐射能量加热并溶化。所产生的热还使密封边16a的端面16d溶化。激光束L沿密封边16a在前灯玻璃16的整个长度范围内被扫描，同时保持激光束L相对于密封边16a的端面16c的倾斜角恒定不变，以便于将前灯玻璃1 6和灯体14粘接在一起。
如业已描述过的那样，在第一个实施例的车灯单元10中，前灯玻璃16和灯体14利用在被粘接的表面，即前灯玻璃1 6的密封边16a的端面16d和灯体14的接受表面14b之间所实施的激光束焊接将前灯玻璃16和灯体14直接粘接在一起。这使得可以在这两个被粘接的表面基本上不产生毛刺的情况下完成强力粘接。于是，被粘接表面周围的那部分的外观得到改善。
在第一个实施例的车灯单元10中，密封边16a的端面16d形成在朝向外周边弯曲预定角度的端部16c处。这使得可以通过引导激光束由与密封边16a的端面16d垂直的方向通过密封边16a的端部16c的方式将激光束L照射到灯体14的接受表面14b上。以下将描述所产生的效果。
在粘接过程中激光束L的穿透距离相当于表示密封边16a的端部16c的厚度的距离D1。距离D1远远短于在激光束L被引导穿透透明压板104和密封边16a情况下的激光束穿透距离(即通过将透明压板104的厚度与作为图8所示的密封边2a的整个长度的距离D0相加所得到的距离)。也就是说，D1＜＜D0。
如果激光束从与密封边16a的端面16d大致垂直的方向照射，那么可以通过对密封边16a的基端部分施加压力使前灯玻璃16受压，如图2中实线箭头所示。(虚线箭头表示在激光束辐射穿透透明压板104和密封边16a的情况下前灯玻璃施压的位置。)这使得可以使密封边16a的端面16d在其宽度范围内以均匀的压力紧贴接受表面14b。因此，可以很容易地在被粘接表面的整个宽度范围内保证所要求的粘接强度。
第一个实施例的具有直接粘合在一起的前灯玻璃和灯体的车灯单元具有得到改善的被粘接表面周围部的外观质量和前灯玻璃和灯体之间的充分增强了的粘接强度。
由于第一个实施例的被粘接表面相对于车灯的基准轴Ax倾斜一个预定的角度，可以获得以下有益的效果。
在密封边16a的端面16d或接受表面14b由于不够光滑而具有波纹状不规则度，使得在它们之间的区域产生间隙的情况下，由于被粘接表面是倾斜的，所以作用在待粘接的那些器件上的压力引起它们之间的滑动。这种滑动的作用将在两器件之间的区域中产生的间隙消除，结果使得在被粘接表面的整个长度范围内它们可以紧贴。因此，可以防止粘接缺陷。
在这个实施例中，灯体的接受表面14b可以带有一个外肋板14c，该外肋板14c在沿前灯玻璃16的密封边16a的端部16c的外侧表面16e的朝外方向上突起、使得该外肋板14c紧贴密封边16a。这使得可以防止由于在粘接过程中所施加的压力在密封边16a的端面16d和该接受表面之间产生不必要的滑动。
图4是类似于图2的视图，它描述的是第一实施例的第一个改进示例。
参照图4，所述的得到改进的例子的基本结构与前述实施例的结构基本相同。然而，在该改进例子中，一个在沿前灯玻璃16的密封边16a的内侧表面16f的朝外方向上突起的内肋板14d被加在灯体14的接受表面14b上。
以上确定的结构使得激光束可以从大致与密封边16a的端面16d垂直的方向照射到内肋板14d的外侧表面14e上，以便于将内肋板14d加热并溶化不考虑照射方向的移动。因此，内肋板14d的外侧表面14e和密封边16a的内侧表面16f可以形成第二粘接表面。这使得可以进一步地增强前灯玻璃16和灯体14之间的粘接强度。
图5是类似于图2的视图，它描述的是第一实施例的第二个改进示例。
参照该图，第二个得到改进的例子的基本结构与前述实施例的结构基本相同。然而，在第二个得到改进的例子中，在灯体14的接受表面14b上形成具有一个凸圆弧状部分的接近端面(approach)。
也就是说，接受表面14b被制作成凸圆弯曲形状，使得激光束L的辐射能量可以通过在粘接操作的较早阶段将密封边16a的端面16d和接受表面14b之间的接触部分设定为一个较小的值而被集中。在接受表面14b被加热溶化过程中接触部分逐渐扩展。因此，粘接过程的工作效率得到改善。在激光焊接完成时，被粘接表面被制作成类似前述实施例的倾斜表面。
接近端面R也可以形成在密封边16a的端面16d上，而不是形成在接受表面14b上。这样做与改进例子效果相同。
图6是类似于图2的视图，它描述的是第一实施例的第三个改进示例。
如图所示，被改进例子的前灯玻璃14和灯体14之间的被粘接表面周围的部分与前述例子相同。然而，在第三个例子中，前灯玻璃16的灯玻璃16g被制成弯曲形状，密封边16a的基端部分16h带有比较大的角。
在使用图8中所示的激光束焊接方法通过密封边16a照射接受表面14b、向前述前灯玻璃16的密封边16a的基端部分16h发射激光束的情况下，在透明压板104和前灯玻璃16中的激光束的光路变得十分复杂并难以建立和控制。因此，这一方法通常是不实用的，原因在于该方法难以控制激光束准确到达接受表面14b。在这个得到改进的例子中，激光束L照射密封边16a的端部16c是从相对于密封边16a的端部16c倾斜上方照射的。这个方法使得激光束可以准确地到达接受表面14b，而对前灯玻璃16的设计没有限制。
在这个得到改进的例子中，激光束L不需要穿透透明压板104。因此，该板可以用由不透明的材料构成的另外类型的压板代替。这适用于另外一些实施例和得到改进的例子。
以下将描述本发明的第二个实施例。
图7是类似于图2的视图，它描述的是这个实施例的车灯单元的几个主要部分。
在第二个实施例中，其基本结构除前灯玻璃16和灯体14之间的那些粘接表面之外与第一个实施例的结构相同。
在这个实施例中，前灯玻璃16和灯体14之间的那些粘接表面被设置得基本上与图中的垂直方向(粘接过程中所施加的压力的方向)正交。密封边16a的端面16d被制作成具有一个弧状部分的凸圆表面。另一方面，灯体14的接受表面14b被制作成与前述凸圆表面对应的波状凹面。波状凹面的中心部分带有一个紧靠凸圆表面的小突起14bl。
在这个实施例中，在密封边16a的端部16c上沿其整个长度范围形成向外周边突出的凸缘部分16k。凸缘部分16k的上表面构成激光束接受表面16j。激光束接受表面16j被制作成具有一个圆弧状部分的凸圆表面，以便于接受按照与基准轴线(图中的垂直轴线)成大约60°角倾斜的入射方向照射的激光束L。入射在激光束接受表面16j上的激光束L被聚焦，而后被向下折射。于是，激光束L被导向密封边16a的端面16d。
业已被导向端面16d的激光束L照射到与端面16d接触的接受表面14b的小突起14bl上。小突起14b1被加热并溶化，结果使得随着溶化的进行接触面逐渐扩大直至端面16d最终在整个凸圆表面范围内被焊接到接受表面14b上为止。
在这个实施例中，在前灯玻璃16和灯体14之间的粘接过程中激光束L的穿透距离相当于从激光接受表面16j至密封边16a的端面16d的距离D2。这一距离远远短于在激光束L的辐射穿过透明压板104和密封边16a的情况下的穿透距离(即通过将透明压板104的厚度与图8所示的密封边2a的全长的距离Do相加所得到的距离)。也就是说，D2＜＜Do。
在激光束L从与被粘接表面倾斜的方向照射时，可以通过对密封边16a的基端部分加压的方式对前灯玻璃16加压，如图7中实线箭头符号所指示的那样。(虚线箭头符号表示在激光辐射穿透透明压板104和密封边16a时前灯玻璃16受压的位置。)这使得可以使密封边16a的端面16d以均匀的压力横跨接受表面14b的宽度紧靠接受表面14b。因此，很容易保证横跨被粘接表面的整个宽度所需要的粘接强度。
在根据该实施例的、具有直接粘合在一起的前灯玻璃和灯体的车灯单元中，在改善被粘接表面周围的外观质量的同时，前灯玻璃和灯体之间的粘接强度得到加强。
在这个实施例中，被粘接的表面基本上与垂直轴正交。这使得可以简化用于形成前灯玻璃16和灯体14的金属模具。由于被粘接表面是通过将凸圆表面(密封边16a的端面16d)和波状凹面(灯体14的接受表面14b)相组合而确定的，可以获得以下有益的效果。
在密封边16a的端面16d和接受表面14b之间的区域由于上述那些表面至少有一个表面光滑度不足而产生间隙的情况下，粘接表面是通过将凸圆表面和波状凹面相组合形成的，在作用于前灯玻璃16和灯体14之间的垂直方向的压力下，小突起14bl被加热并溶化。随着加热和溶化过程的进行，前灯玻璃16和灯体14之间的接触部分逐渐扩大。因此，在密封边16a的端面16d和接受表面14b之间区域中的间隙由于施加在先期加热溶化的其他接触部分高压很容易被消除。因此，密封边16a的端面16d和接受表面14b可以可靠地沿被粘接表面的整个长度紧贴，结果可以防止出现粘接缺陷。
业已就车灯单元10被制成指示灯的情况对本发明的若干优选实施例作过说明。通过将上述实施例的结构用于其他种类的车灯单元，也可以获得与上述实施例相类似的效果。

Claims (11)

1．一种车灯单元，所述的车灯单元包括：一个前灯玻璃和一个灯体，所述的前灯玻璃包括一个形成在所述的前灯玻璃的外周边并且在所述的前灯玻璃的朝外的方向上延伸的一个密封边，所述的灯体包括与所述的密封边的端面紧靠的密封边接受表面，一个激光束接受表面形成在所述的密封边的外侧表面上，借此使由与所述的灯单元的基准轴线成锐角的方向被引导至所述的激光束接受表面的激光束通过所述的密封边并且照射到所述的密封边接受表面上，利用激光束焊接将所述的密封边的端面和所述的密封边接受表面粘接在一起，形成所述的前灯玻璃和所述的灯体之间的被粘接表面。
2．根据权利要求1所述的灯体单元，其特征在于所述的密封边的端部朝向所述的前灯玻璃的外周边弯曲一个相对于所述的基准轴的锐角。
3．根据权利要求1所述的灯体单元，其特征在于所述的灯体进一步包括一个形成在所述的灯体接受表面上并且沿所述的密封边的端部外侧边面在所述的朝外的方向伸出的外肋板。
4．根据权利要求1所述的灯体单元，其特征在于所述的灯体进一步包括一个形成在所述的灯体的密封边接受表面上并且沿所述的密封边的内侧边面在所述的朝内的方向伸出的内肋板。
5．根据权利要求2所述的灯体单元，其特征在于所述的灯体进一步包括一个形成在所述的灯体的密封边接受表面上并且沿所述的密封边的内侧边面在所述的朝内的方向伸出的内肋板。
6．根据权利要求1所述的灯体单元，其特征在于所述的密封边接受表面的至少一部分呈凸圆状弯曲。
7．一种制造一种车灯单元的方法，该方法包括如下步骤：
提供一个具有一个在所述的前灯玻璃的外周边围绕所述的前灯玻璃并且从所述的前灯玻璃向外伸出的密封边的前灯玻璃；
提供一个具有在对应于所述的密封边的端面的一个位置从所述的灯体突出的激光束接受表面的灯体；
使所述的密封边的端面紧靠所述的接受表面；以及
将激光束导向所述的激光束接受表面使激光束通过所述的密封边以便于将所述的接受表面的一部分加热并熔化，与此同时将所述的前灯玻璃压向所述的灯体，借此，将所述的前灯玻璃和所述的灯体粘接在一起。
8．根据权利要求7所述的方法，其特征在于所述的密封边的端部朝向所述的前灯玻璃的外周边弯曲一个相对于所述的基准轴的锐角。
9．根据权利要求7所述的方法，其特征在于所述的灯体进一步包括一个形成在所述的灯体接受表面上并且沿所述的密封边的端部外侧边面在所述的朝外的方向伸出的外肋板。
10．根据权利要求7所述的方法，其特征在于所述的灯体进一步包括一个形成在灯体的密封边接受表面上并且沿所述的密封边的内侧边面在朝内的方向伸出的内肋板。
11．一种制造一种车灯单元的方法，该方法包括如下步骤：
提供一个具有一个在所述的前灯玻璃的外周边围绕所述的前灯玻璃并且从所述的前灯玻璃向外伸出的密封边的前灯玻璃，所述的密封边具有一个朝向所述的外周边弯曲一个预定的角度的端部；
提供一个具有在对应于所述的密封边的端面的一个位置从所述的灯体突出的激光束接受表面的灯体，所述的接受表面基本上按照所述预定的角度倾斜；
使所述的密封边的端面紧靠所述的接受表面；以及
引导所述的激光束通过基本上垂直于所述的端面的所述的密封边到达激光束接受表面以便于将所述的接受表面的一部分加热并熔化，与此同时将所述的前灯玻璃压向所述的灯体，借此，将所述的前灯玻璃和所述的灯体粘接在一起。
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