JP4678829B2 - 車輌用灯具の製造方法 - Google Patents

車輌用灯具の製造方法 Download PDF

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Publication number
JP4678829B2
JP4678829B2 JP2005018229A JP2005018229A JP4678829B2 JP 4678829 B2 JP4678829 B2 JP 4678829B2 JP 2005018229 A JP2005018229 A JP 2005018229A JP 2005018229 A JP2005018229 A JP 2005018229A JP 4678829 B2 JP4678829 B2 JP 4678829B2
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Japan
Prior art keywords
housing
transparent cover
welding
welding surface
build
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Expired - Fee Related
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JP2005018229A
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English (en)
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JP2006205441A (ja
Inventor
一廣 山▲崎▼
亮介 安田
富士彦 杉山
三千彦 鈴木
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Koito Manufacturing Co Ltd
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Koito Manufacturing Co Ltd
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Publication date
Application filed by Koito Manufacturing Co Ltd filed Critical Koito Manufacturing Co Ltd
Priority to JP2005018229A priority Critical patent/JP4678829B2/ja
Priority to KR20060006782A priority patent/KR100749576B1/ko
Priority to CN200610006054A priority patent/CN100575055C/zh
Priority to US11/338,960 priority patent/US7591698B2/en
Priority to GB0601508A priority patent/GB2427383B/en
Publication of JP2006205441A publication Critical patent/JP2006205441A/ja
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Publication of JP4678829B2 publication Critical patent/JP4678829B2/ja
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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
    • 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
    • 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
    • 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
    • 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
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B29C65/7844—Holding or clamping means for handling purposes cooperating with specially formed features of at least one of the parts to be joined, e.g. cooperating with holes or ribs of 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
    • 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
    • B29C66/024—Thermal pre-treatments
    • B29C66/0242—Heating, or preheating, e.g. drying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C66/112—Single lapped 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
    • B29C66/01—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
    • 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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • 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
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5346—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat
    • B29C66/53461—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat joining substantially flat covers and/or substantially flat 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
    • B29C66/51—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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • 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
    • B29C66/73365—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 at least one of the parts to be joined being transparent or translucent to visible light
    • 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
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8126—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
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  • Physics & Mathematics (AREA)
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  • Toxicology (AREA)
  • Optics & Photonics (AREA)
  • Thermal Sciences (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)
  • Securing Globes, Refractors, Reflectors Or The Like (AREA)

Description

本発明は新規な車輌用灯具の製造方法に関する。詳しくは、透明カバーとハウジングとを光線溶着によって接合する車輌用灯具の製造方法において、透明カバーとハウジングとの接合を確実に為す技術に関する。
車輌灯具、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透明カバーを取り付ける工程が必要である。
従来にあっては、透明カバーとハウジングとの間の取付には、透明カバー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、透明カバー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、シール脚や溝は透明カバー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、透明カバー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。
そこで、透明カバー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。透明カバー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、透明カバー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、透明カバー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、これが前方から透明カバーを通して視認されて外観を損ねるという問題がある。
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。
さらに、透明カバーとハウジングをレーザー溶着等の光線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、透明カバー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、透明カバーにも熱伝導させて溶融させ、両者が相溶して融着される。
ところで、レーザー溶着にあっては、透明カバー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溶着不良を起こす。
しかしながら、車輌用灯具の透明カバーとハウジングは樹脂成形品であり、成形後の収縮やソリ、撓み等の影響から、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、透明カバー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、透明カバー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透明カバーに伝達せず、溶着が不能になる。
樹脂成形品同士をレーザ溶着するに際して、互いに溶着される２つの部材の上記したような成形上の問題に起因する互いの溶着部の密着性の悪さをカバーするために、レーザ溶着に先だって、２つの樹脂成形品の溶着部を互いの樹脂材料の熱変形温度以上の温度で予備加熱して互いの溶着部を軟化させておき、これによって、互いの溶着部を圧着させたときに、軟化している溶着部が変形して、両溶着部が密着するようにしてからレーザ溶着をする技術が特許文献１に示されている。
特開２００４−７４７３４号公報
ところで、上記特許文献１に示された技術にあっては、予備加熱によって互いに溶着される２つの樹脂成形品の溶着部を全周に亘って加熱軟化させている。従って、２つの溶着部を密着させるために、一方の樹脂成形品を他方の樹脂成形品に対した圧着させたときに、２つの溶着部の全周に亘って変形を生じ、これによって、基準となる面が消失するため、互いに接合させる部材の位置精度が悪化するという問題がある。
また、溶着部が全周に亘って軟化しているため、必要以上に押し込まれる部分が生じ、そのような部分では、押し込まれた樹脂が溶着部から外にはみ出してバリとなり、製品の見映えを損なうという問題がある。
そこで、本発明は、透明カバーとハウジングとをレーザー溶着等の光線溶着によって接合するに際して、位置精度の悪化や見映えの悪化を生じること無しに、レーザ溶着時に透明カバー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。
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、透明カバー及びハウジングはそれぞれ溶着面を備え、ハウジングの溶着面のうち、下記圧着工程における加圧方向に垂直な面に対して所定の角度を有する傾斜部には、設計上の溶着面の上に肉付けした肉盛部が形成され、該肉盛部を加熱して軟化させる予備加熱工程と、透明カバーの溶着面の傾斜部がハウジングの上記肉盛部に当接し、該肉盛部が変形して傾斜部以外の部分においても透明カバーの溶着面がハウジングの溶着面と接触した状態になる圧着工程と、互いに圧着されている透明カバーの溶着面とハウジングの溶着面との全周に亘って光線を照射して溶着する溶着工程とを備えたものである。
従って、本発明車輌用灯具の製造方法にあっては、圧着工程では肉盛部のみが変形をして、透明カバーの溶着部とハウジングの溶着部とが確実に接触する。
本発明車輌用灯具の製造方法は、透明カバーとハウジングとが光線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、透明カバー及びハウジングはそれぞれ溶着面を備え、ハウジングの溶着面のうち、下記圧着工程における加圧方向に垂直な面に対して所定の角度を有する傾斜部には、設計上の溶着面の上に肉付けした肉盛部が形成され、該肉盛部を加熱して軟化させる予備加熱工程と、透明カバーの溶着面の傾斜部がハウジングの上記肉盛部に当接し、該肉盛部が変形して傾斜部以外の部分においても透明カバーの溶着面がハウジングの溶着面と接触した状態になる圧着工程と、互いに圧着されている透明カバーの溶着面とハウジングの溶着面との全周に亘って光線を照射して溶着する溶着工程とを備えたことを特徴とする。
従って、本発明車輌用灯具の製造方法にあっては、透明カバーの溶着面とハウジングの溶着面とを接触させる工程に先だって、予備加熱工程によってハウジングの溶着面の傾斜部に形成された肉盛部が軟化されているので、圧着工程において上記肉盛部が変形することによって透明カバーとハウジングの互いの溶着部の肉盛部は勿論のこと、肉盛部が形成された部分以外の部分が確実に接触され、後のレーザー溶着が確実に為される。また、バリの発生箇所を、全周ではなく、肉盛部を形成した部分にのみ限定することができるので、全体としての見映えの向上につながる。また、上記肉盛部は、圧着工程における加圧方向に垂直な面に対して所定の角度を有する傾斜部に形成されているので、透明カバーとハウジングとの間で最も間隙が生じやすい加圧方向に垂直な面に対して所定の傾斜を有する傾斜部で透明カバーの溶着面とハウジングの溶着面の非接触が防止される。
請求項２に記載した発明にあっては、肉盛部が形成された傾斜部の圧着工程における加圧方向に垂直な面に対する角度が１５度以上になっているので、透明カバーとハウジングとの間で最も間隙を生じやすい傾斜部での非接触がより確実に防止される。
以下に、本発明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。
図１に車輌用灯具の一例を示す。
車輌用灯具１０は透明カバー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、開口縁の前面３２が溶着面とされる。そして、上記溶着面３２の一部にほぼ前後方向に傾斜した傾斜部３２ａが形成されている。また、上記ハウジング３０の開口縁の裏側には凹溝状をした被係合部３３が形成されている。このようなハウジング３０は光線吸収性、例えば、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。
透明カバー２０は光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。そして、周縁部の後面に上記ハウジング３０の溶着面３２に倣う形状の溶着面２１が形成されている。
上記透明カバー２０はその溶着面２１がハウジング３０の溶着面３２に光線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。
上記透明カバー２０の溶着面２１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、透明カバー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、成形後の収縮やソリ、撓み等の影響から、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、透明カバー２０の溶着面２１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。
図２乃至図７に本発明車輌用灯具の製造方法の実施の形態を示す。
上記ハウジング３０の溶着面３２の一部には肉盛部が形成されている。図２は透明カバー２０とハウジング３０とをやや離間させた状態で示すものである。図２（ｂ）は図２（ａ）のＹ１視図であり、Ｙ１視で透明カバー２０とハウジング３０の溶着面２１、３２はなだらかな曲面をしている。また、図２（ｃ）は図２（ａ）のＹ２視図であり、Ｙ２視で透明カバー２０とハウジング３０の溶着面２１、３２には透明カバー２０をハウジング３０に圧着させる圧着工程における加圧方向（図６の矢印Ｐ参照）に垂直な面に対して大きな角度を有する傾斜部２１ａ、３２ａを有している。図３（ａ）に示すように、透明カバーａとハウジングｂの溶着面ｃ、ｄが互いに加圧方向（図３の矢印Ａ参照）に対して垂直な面である場合には、例えば、透明カバーａとハウジングｂとの間に加圧方向Ａに対して垂直な方向でのずれがあっても、２つの溶着面ｃ、ｄは全面に亘って接触することが出来るが、図３（ｂ）に示すように、透明カバーａとハウジングｂの溶着面ｅ、ｆに加圧方向Ａに対して大きな角度θ、例えば、１５度以上の角度で傾斜した部分ｅ′、ｆ′がある場合、透明カバーａとハウジングｂとの間にずれが生じると、互いの溶着面ｅ、ｆの上記傾斜した部分ｅ′、ｆ′間で間隙ｇが生じてしまう。
そこで、上記車輌用灯具１０にあっては、透明カバー２０の溶着面２１の傾斜部２１ａ及びハウジング３０の溶着面３２の傾斜面３２ａの双方又はいずれか一方に肉盛部を形成する。なお、上記傾斜部２１ａ及び傾斜面３２ａの後述する圧着工程における加圧方向に垂直な面に対する角度α（図４（ａ）参照）は、例えば、１５度以上となっている。
なお、肉盛部を形成する箇所は、例えば、透明カバー２０の設計データとハウジング３０の設計データとを正規の組付位置からオフセットさせ、上記オフセット量に対する透明カバー２０の溶着部２１とハウジング３０の溶着部３２との間の間隙が大きくなる部分に設けるようにすると良い。このような部分、例えば、上記傾斜部２１ａ、３２ａでは、透明カバー２０及び／又はハウジング３０に変形がある場合、他の部分で互いの溶着面２１と３２とがぴったりと接触しても、互いの間に間隙が出来たり、逆に、オーパーラップしたりする。そこで、このような部分に予めオーバーラップするように肉盛を形成しておき、圧着工程の前に予備加熱によって該肉盛部を軟化させておくことによって、当該部分２１ａ、３２ａが確実に接触すると共に、オーパーラップしている部分は加圧時に変形して、余分な材料樹脂は側方にはみ出し、これによって、溶着面２１、３２の他の部分で確実に接触することになる。
図４に上記した肉盛部の形成例を示す。透明カバー２０の溶着面２１の傾斜部２１ａとハウジング３０の溶着面３２の傾斜部３２ａとの間に、例えば、図４（ａ）に示すように、最大でＧ１で示す間隙が生じると予想される場合、この間隙Ｇ１を埋めるのに必要な大きさより僅かに大きな肉盛部３４をハウジング３０に形成する。なお、肉盛部は透明カバー２０の方に形成しても良いし、また、透明カバー２０とハウジング３０の双方に形成しても良い。
そして、先ずハウジング３０を下治具５０に支持させる（図６参照）。下治具５０にはハウジング３０の後面を受け入れる受け入れ凹部５１が形成されており、ハウジング３０は、開口面を上方に向けた姿勢でその後面が下治具５０の受け入れ凹部５１に受け入れられて支持される。また、下治具５０の受け入れ凹部５１の開口縁部には係合部５２が形成されており、ハウジング３０が下治具５０の受け入れ凹部５１に受け入れられると、ハウジング３０の開口縁部の背面に形成された被係合部３３が下治具５０の係合部５２と係合される。従って、ハウジング３０に多少の変形があった場合でも、ハウジング３０の被係合部３３が下治具５０の係合部５２と係合されることによって、ハウジング３０の被係合部が形成された部分が剛性の高い下治具５０によって強制的に位置規定され、これによって、ハウジング３０は設計形状に近い形状に強制される。
上記したように、ハウジング３０が下治具５０に支持されると、加熱体６０が下治具５０に支持されているハウジング３０の上方で上治具７０に支持されている透明カバー２０とハウジング３０との間に移動されてきて、その伝熱端６１がハウジング３０の肉盛部３４に近接され（図５参照）て予備加熱工程が行われる。なお、加熱体６０は、例えば、抵抗加熱式のヒーターブロックであり、上治具７０と下治具５０との間に出し入れ自在に構成されている。上記加熱体６０の伝熱端６１はハウジング３０に形成された肉盛部３４の形状に適合するように予め成形されている。また、加熱体６０の種類は問わないが、例えば、熱板や抵抗加熱体が適用可能である。なお、上記したように、抵抗加熱体を加熱体とした場合は、熱エネルギーの損失が少なく、また、温度のコントロールが容易であり、ハウジング３０の肉盛部３４を所望の温度に加熱することが容易である。
また、上治具７０は光線透過性のある材料で形成され、下面に透明カバー２０の前面部を受け入れる受け入れ凹部７１が形成されている。そして、透明カバー２０は上治具７０の受け入れ凹部７１に受け入れられた状態で支持される。なお、上治具７０への透明カバー２０の支持はエアによる吸引等適宜の手段によって為されて良い。
上記した予備加熱工程によって、肉盛部３４が軟化点まで加熱され、該肉盛部３４が荷重を受けると容易に変形することが可能な状態とされる。
そして、予備加熱工程によって、肉盛部３４が軟化された状態で、透明カバー２０を支持した上治具７０が下降してきて、透明カバー２０の溶着面２１をハウジング３０の溶着面３２に密着させる圧着工程が行われる。そして、上治具７０と共に透明カバー２０が下降してくると、先ず、透明カバー２０の溶着面２１の傾斜部２１ａがハウジング３０の肉盛部３４に当接する（図４（ｂ）の実線で示す状態参照）。この状態では、傾斜部２１ａ以外の透明カバー２０の溶着面２１はハウジング３０とは接触していない。図４（ｂ）の実線で示す状態から透明カバー２０を介して上治具７０による圧力が加えられると、軟化している肉盛部３４が変形をして、透明カバー２０の図４（ｂ）の実線で示す状態からさらに下降することが許容される。そして、透明カバー２０の下降によって透明カバー２０の溶着面２１の傾斜部２１ａが図４（ｂ）の１点鎖線で示す位置まで来ると、傾斜部２１ａ以外の部分においても透明カバー２０の溶着面２１がハウジング３０の溶着面３２と接触した状態となる。このようにして、全周に亘って、透明カバー２０の溶着面２１とハウジング３０の溶着面３２とが接触される。なお、肉盛部３４が形成されていなかったとすると、ハウジング３０の溶着面３２の傾斜部３２ａは図４（ｂ）の破線で示す位置にあり、傾斜部２１ａ、３２ａ以外の部分で透明カバー２０とハウジング３０の溶着面２１、３２が接触したときに、図４（ｂ）の１点鎖線で示す位置にある透明カバー２０の傾斜部２１ａと同じく破線で示す位置にあるハウジング３０の傾斜部３２ａとの間には間隙Ｇ２が生じてしまう。
上記したように、圧着工程により、透明カバー２０の溶着面２１とハウジング３０の溶着面３２とが全周に亘って接触した状態（図６参照）で、ハウジング３０の溶着面３２への光線の照射による光線溶着が行われる。例えば、レーザヘッド８０を上治具７０の上方に位置させ、例えば、６軸ロボット等の制御手段によりレーザヘッド８０の高さ、姿勢等を制御しながらレーザ光８１を上治具７０及び透明カバー２０を透過させてハウジング３０の溶着面３２に照射する。このとき、下治具５０と上治具７０とを同期回転させることによってレーザヘッド８０を支持しているロボットには複雑な動きのみを担わせることが出来る。レーザ光８１がハウジング３０の溶着面３２に照射されることによって、ハウジング３０の溶着面３２が発熱し、ハウジングの溶着面３２が発熱すると、該発熱が透明カバー２０の溶着面２１に伝達され、両溶着面３２、２１が共に加熱され、相溶状態となり、２つの溶着面３２．２１が接触した界面においてハウジング３０及び透明カバー２０の材料樹脂が一体化する。このようにして、ハウジング３０に透明カバー２０が一体的に固定される。
なお、ハウジング３０の溶着面３２に照射される光線はレーザ光に限られるものではない。すなわち、レーザー光の他、可視光線、紫外線、赤外線等の干渉性（coherent）又は非干渉性（non-coherent）の電磁波のうちの適宜のもので良く、当該電磁波の照射によってハウジング３０溶着面３２を励起状態とすることが出来るものであればよい。すなわち、ハウジング３０の材料には照射される電磁波の波長と振動周期が一致するラジカルによって構成される分子構造を有するものが使用される。なお、ハウジング３０の材料が当該光線の照射によって励起状態となるものでない場合は、当該光線の照射により励起状態となる材料をハウジング３０の材料に混練りするか、又は、そのような材料をハウジング３０の溶着面３２に塗布等によって付着させても良い。例えば、レーザーを照射する場合は、レーザー吸収材をハウジング３０の材料に混練りするか、レーザー吸収材をハウジング３０の溶着面３２に塗布等により付着させればよい。
上記したように、本発明にあっては、圧着工程により透明カバー２０の溶着面２１（傾斜部２１ａを含む）とハウジング３０の溶着面３２（傾斜部３２ａを含む）とが全周に亘って確実に接触するので、光線照射による溶着が確実に為される。また、予備加熱工程では、肉盛部３４を加熱軟化させるので、圧着工程における加圧による変形が肉盛部３４にのみ生じ、灯具全体の寸法精度が損なわれることがない。また、加圧による変形に伴って生じる軟化した材料樹脂のはみ出しによるバリの発生箇所を、全周ではなく、肉盛部を形成した部分にのみ限定することができるので、全体として見映えの向上につながる。
なお、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。
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透明カバー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。
車輌用灯具の一例を示す概略断面図である。 透明カバーとハウジングとを上下に離間した状態で示すものであり、（ａ）は概略平面図、（ｂ）は（ａ）のＹ１矢視図、（ｃ）は（ａ）のＹ２矢視図である。 加圧方向に対して垂直な面に対する傾斜角度とずれの関係を示すものであり、（ａ）は傾斜角度が無い場合を示す概略側面図、（ｂ）は大きな傾斜角度を有する場合示す概略側面図である。 肉盛部の形成部位と肉盛部の形成による作用を示すものであり、（ａ）は肉盛部が無い場合における透明カバーとハウジングとの間に生じる間隙を示す概略拡大側面図、（ｂ）は圧着工程における作用を示す概略拡大側面図である。 予備加熱工程を概念的に示す概略斜視図である。 圧着工程を示す一部切欠側面図である。 溶着工程を概念的に示す概略斜視図である。
符号の説明
１０…車輌用灯具、２０…透明カバー、２１…溶着面、２１ａ…傾斜部（加圧方向に垂直な面に対して所定の傾斜を有する部分）、３０…ハウジング、３２…溶着面、３２ａ…傾斜部（加圧方向に垂直な面に対して所定の傾斜を有する部分）、３４…肉盛部、８１…レーザ光（光線）

Claims (2)

  1. 透明カバーとハウジングとが光線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、
    透明カバー及びハウジングはそれぞれ溶着面を備え、
    ハウジングの溶着面のうち、下記圧着工程における加圧方向に垂直な面に対して所定の角度を有する傾斜部には、設計上の溶着面の上に肉付けした肉盛部が形成され、該肉盛部を加熱して軟化させる予備加熱工程と、
    透明カバーの溶着面の傾斜部がハウジングの上記肉盛部に当接し、該肉盛部が変形して傾斜部以外の部分においても透明カバーの溶着面がハウジングの溶着面と接触した状態になる圧着工程と、
    互いに圧着されている透明カバーの溶着面とハウジングの溶着面との全周に亘って光線を照射して溶着する溶着工程とを備えた
    ことを特徴とする車輌用灯具の製造方法。
  2. 肉盛部が形成された上記傾斜部の圧着工程における加圧方向に垂直な面に対する角度が、１５度以上になっている
    ことを特徴とする請求項１に記載の車輌用灯具の製造方法。
JP2005018229A 2005-01-26 2005-01-26 車輌用灯具の製造方法 Expired - Fee Related JP4678829B2 (ja)

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US7591698B2 (en) 2009-09-22
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