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JP3972621B2 - Vehicle lamp and laser welding method thereof - Google Patents

Vehicle lamp and laser welding method thereof Download PDF

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Publication number
JP3972621B2
JP3972621B2 JP2001311304A JP2001311304A JP3972621B2 JP 3972621 B2 JP3972621 B2 JP 3972621B2 JP 2001311304 A JP2001311304 A JP 2001311304A JP 2001311304 A JP2001311304 A JP 2001311304A JP 3972621 B2 JP3972621 B2 JP 3972621B2
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JP
Japan
Prior art keywords
outer lens
housing
laser
light
welding
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
JP2001311304A
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Japanese (ja)
Other versions
JP2003123506A (en
Inventor
賢一 浅香
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ichikoh Industries Ltd
Original Assignee
Ichikoh Industries Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ichikoh Industries Ltd filed Critical Ichikoh Industries Ltd
Priority to JP2001311304A priority Critical patent/JP3972621B2/en
Publication of JP2003123506A publication Critical patent/JP2003123506A/en
Application granted granted Critical
Publication of JP3972621B2 publication Critical patent/JP3972621B2/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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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
    • B29C65/1677—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
    • B29C65/1629—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
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1664—Laser beams characterised by the way of heating the interface making use of several radiators
    • B29C65/1667—Laser beams characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous laser 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
    • B29C66/05—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
    • B29C66/11—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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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/05—Particular design of joint configurations
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    • 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
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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
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/23—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations
    • B29C66/232—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being multiple and parallel or being in the form of tessellations said joint lines being multiple and parallel, i.e. the joint being formed by several parallel joint lines
    • 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
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • 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
    • B29C66/345—Progressively making the joint, e.g. starting from the middle
    • B29C66/3452—Making complete joints by combining partial 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
    • B29C66/53—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
    • B29C66/5342—Joining single elements to open ends of tubular or hollow articles or to the ends of bars a substantially flat extra element being placed between and clamped by the joined single elements and the end of said tubular or hollow articles
    • B29C66/53421—Joining single elements to open ends of tubular or hollow articles or to the ends of bars a substantially flat extra element being placed between and clamped by the joined single elements and the end of said tubular or hollow articles said substantially flat extra element being flexible, e.g. a membrane
    • 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
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    • 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
    • B29C66/541—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 a substantially flat extra element being placed between and clamped by the joined hollow-preforms
    • B29C66/5412—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 a substantially flat extra element being placed between and clamped by the joined hollow-preforms said substantially flat extra element being flexible, e.g. a membrane
    • 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
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    • 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
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    • B29C66/5414—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 a substantially flat extra element being placed between and clamped by the joined hollow-preforms said substantially flat extra element being rigid, e.g. a plate
    • 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
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    • 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
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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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    • B29C66/50—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
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    • 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C66/61—Joining from or joining on the inside
    • 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
    • B29C66/70—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
    • B29C66/72—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 structure of the material of the parts to be joined
    • B29C66/723—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 structure of the material of the parts to be joined being multi-layered
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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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
    • B29C66/739—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
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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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Description

【０００１】
【発明の属する技術分野】
この発明は、例えばリヤランプとして適用される、インナシート（フィルム）やインナレンズ等の光透過部材を灯室内に設けた車両用灯具およびそのレーザ溶着方法に関する。
【０００２】
【従来の技術】
車両用灯具では、アウタレンズが、透明な熱可塑性樹脂材で構成されると共に、ハウジングと共働して灯室を画成するように前記ハウジングの開口部を覆うようにして固定されている。
【０００３】
また、インナシート（フィルム）は、見栄え向上の模様付けを目的としてアウタレンズの裏面に接近させて設けられており、インナレンズは、ランプの配光制御と色付けを目的としてアウタレンズの後方に設けられている。
【０００４】
そして、アウタレンズのハウジングへの固定手段としては、振動溶着、超音波溶着等に代表される溶着が短時間で接合が可能であり、接着剤やねじ等の金属部品を使用しないので、それにかかるコストや重量増、環境汚染らの問題が発生しないことから、主流になりつつある。図６は、アウタレンズ２のハウジング４への固定状態を示す。
【０００５】
また、インナシート２０は、図７に示すように、両面テープ１５を介してアウタレンズ２の裏面側に貼り付けられる。すなわち、インナシート２０は、アウタレンズ２の裏面に直接貼着される両面テープ１５を介して貼り付けられる（図７（ａ））か、またはアウタレンズ２の環状リブ３に貼着される両面テープ１５を介して貼り付けられる（図７（ｂ））。
【０００６】
また、インナレンズ２１は、図８に示すように、インナレンズ２１に設けたランス１６によりランス係合させると共に、がたつきやはずれを防止するためにさらにスクリュー１７止めして取り付けられている。
【０００７】
【発明が解決しようとする課題】
しかしながら、振動溶着や超音波溶着は、図６に示すように、アウタレンズ２の環状リブ３の先端とハウジング４の平坦面との溶着となり、溶着部付近に溶着バリや糸引き５が現出するばかりでなく、この部分Ｔが広いダミー幅となってアウタレンズ２の表面側から観察することができ、ひいては外観上の品質の低下を招く、という課題を有している。
【０００８】
また、インナシート２０やインナレンズ２１の取付は、工数が掛かり、ひいてはコスト高を招くばかりでなく、両面テープ１５を用いた工法では、さらに接着後、熱や振動等で剥がれや白化を生じる虞がある、という課題を有している。
【０００９】
そこで、この発明は、アウタレンズおよび光透過部材（インナシートまたはインナレンズ）のハウジングへの固定が、溶着バリや糸引き並びに白化に起因する外観上の品質の低下を伴うことなく比較的簡単な作業で確実に行うことができ、ひいてはコストの低減化をも可能とした車両用灯具およびそのレーザ溶着方法を提供することを目的としている。
【００１０】
【課題を解決するための手段】
前記した目的を達成するため、請求項１の発明は、アウタレンズが、レーザ光に対して透明な熱可塑性樹脂材で構成されると共に、レーザ光に対して吸収性のある熱可塑性樹脂材で構成されたハウジングと共働して光源バルブの設けられる灯室を画成するように前記ハウジングの開口部を覆うようにして固定されており、かつ光透過部材が、透明な熱可塑性樹脂材で構成されると共に、前記光源バルブの光を前記アウタレンズ側に透過するように前記灯室内に設けられている車両用灯具であって、前記アウタレンズは、前記ハウジングの開口部との当接部位を前記アウタレンズ側から照射されるレーザ光により全周に亘ってレーザ溶着することにより前記ハウジングに固定されており、かつ前記光透過部材は、前記アウタレンズと前記ハウジングとの間に挟持されると共に、該挟持部位を少なくとも部分的に前記アウタレンズ側から照射されてアウタレンズおよび光透過部材の該挟持部位を透過したレーザ光によりレーザ溶着することにより前記ハウジングに固定されていることを特徴とする。
【００１１】
このため請求項１の発明では、アウタレンズは、レーザ光に対して透明な熱可塑性樹脂材で構成されているので、アウタレンズ側から照射されるレーザ光はアウタレンズを透過してハウジングに到達する。ハウジングは、レーザ光に対して吸収性のある熱可塑性樹脂材で構成されているので、ハウジングに到達したレーザ光はハウジングに吸収されて熱に変換され、この熱でハウジングの照射部位を溶解させる。この溶解熱はアウタレンズ側にも伝播され、アウタレンズを同様に溶解させる。しかして、アウタレンズとハウジングは、その溶解部同士が融合するレーザ溶着により接合される。アウタレンズは、このようなレーザ溶着をアウタレンズの全周に亘って施すことによって、ハウジングの開口部を覆うようにして固定される。
【００１２】
また、光透過部材は、レーザ光に対して透明な熱可塑性樹脂材で構成されているので、アウタレンズ側から照射されるレーザ光は、アウタレンズおよび光透過部材を透過してハウジングに到達する。ハウジングに到達したレーザ光は、前述したようにハウジングに吸収されて熱に変換され、この熱でハウジングの照射部位を溶解させる。この溶解熱は光透過部材側にも伝播され、光透過部材を同様に溶解させる。しかして、光透過部材とハウジングは、その溶解部同士が融合するレーザ溶着により接合される。光透過部材は、その溶着面にシール性が要求されないので、このようなレーザ溶着は部分的に施されていれば足りる。
【００１３】
また、溶着面は、溶解部同士の融合により形成されるので、溶着バリや糸引きを生じさせることなく形成することができる。
【００１４】
また、請求項２の発明は、請求項１に記載の車両用灯具であって、
前記アウタレンズおよびハウジングのいずれか一方の部材は、他方の部材へ突出する環状リブを一体に形成して構成されており、かつ
前記環状リブは、その幅方向の外側に位置する前記他方の部材へ当接する第１当接面と、その幅方向の内側に位置する前記光透過部材へ当接する第２当接面とからなる段部を先端面に形成して構成されており、
前記アウタレンズおよび光透過部材は、前記第１当接面を前記他方の部材へ当接させると共に、前記第２当接面と他方の部材との間に前記光透過部材を挟持させた状態で、前記アウタレンズ側から照射されるレーザ光によるレーザ溶着により前記ハウジングに固定されていることを特徴とする。
【００１５】
このため請求項２の発明では、環状リブは、アウタレンズに形成される場合はレーザ光に対して透明な熱可塑性樹脂材で構成され、ハウジングに形成される場合はレーザ光に対して吸収性のある熱可塑性樹脂材で構成される。このためアウタレンズ側から照射されるレーザ光は、前者の場合、環状リブ、または環状リブおよび光透過部材を介してハウジングに達するのに対して、後者の場合、直接または光透過部材を介して環状リブの段部に達する。
【００１６】
そして、溶着面は、前者の場合、段部の第１当接面とハウジングとの間および光透過部材とハウジングとの間にそれぞれ形成されるのに対して、後者の場合、アウタレンズと段部の第１当接面との間および光透過部材と段部の第２当接面との間にそれぞれ形成される。
【００１７】
また、レーザ溶着は、前者の場合、ハウジングの溶着面が平坦面であるときは、レーザ光の第１および第２当接面に跨る同一集光径内でのアウタレンズおよび光透過部材の同時溶着が可能であるのに対して、後者の場合、光透過部材が厚いとその分第２当接面の深さが深くなり前記同時溶着が不能となるが、その場合でも、光透過部材の厚さ（第２当接面の深さ）に見合ったレーザ光の少しの移動でアウタレンズおよび光透過部材のレーザ溶着が可能となるので、制御が簡単である。
【００１８】
また、請求項３の発明は、請求項２に記載の車両用灯具であって、
前記環状リブは、前記ハウジングに一体に形成されており、
前記光透過部材は、一般部よりも肉薄に形成される被挟持部を周縁部に有して構成されており、かつ
前記アウタレンズは、アウタレンズを透して照射されるレーザ光による第１当接面へのレーザ溶着により固定されると共に、前記光透過部材は、アウタレンズおよび前記被挟持部を透して照射されるレーザ光による前記被挟持部の第２当接面へのレーザ溶着により固定されていることを特徴とする。
【００１９】
このため請求項３の発明では、被挟持部を薄く形成した分第２当接面の深さも浅くなり、これによりレーザ溶着は、レーザ光の第１および第２当接面に跨る同一集光径内でのアウタレンズおよび光透過部材の同時溶着が可能となる。
【００２０】
また、請求項４の発明は、請求項２または３に記載の車両用灯具のレーザ溶着方法であって、
前記レーザ光を前記第１当接面と第２当接面に跨る集光径を有して照射することにより、前記アウタレンズおよび光透過部材を、前記レーザ光の同一集光径内で同時に溶着することを特徴とする。
【００２１】
このため請求項４の発明では、溶着工程の簡略化を図ることができる。
【００２２】
【発明の実施の形態】
以下、本発明を、実施の形態に基づいて具体的に説明する。なお、図６〜図８に示す部材と同一機能を有する部材は、同一符号を付して説明する。
【００２３】
図１は、本発明の第１実施形態としての車両用灯具１を示す。この車両用灯具１は、アウタレンズ２が、レーザ光１３に対して透明な熱可塑性樹脂材で構成されると共に、レーザ光１３に対して吸収性のある熱可塑性樹脂材で構成されたハウジング４と共働して光源バルブ１２の設けられる灯室１１を画成するようにハウジング４の開口部を覆うようにして固定されており、かつ光透過部材としてのインナシート２０が、レーザ光１３に対して透明な熱可塑性樹脂材で構成されると共に、光源バルブ１２の光をアウタレンズ２側に透過するように灯室１１内に設けられている。
【００２４】
そして、アウタレンズ２は、ハウジング４の開口部との当接部位をアウタレンズ２側から照射されるレーザ光１３により全周に亘ってレーザ溶着することによりハウジング４に固定されており、かつインナシート２０は、アウタレンズ２とハウジング４との間に挟持されると共に、該挟持部位をアウタレンズ２側から照射されるレーザ光１３により少なくとも部分的にレーザ溶着することによりハウジング４に固定されている。図１中、符号６は、反射面であり、符号８は、レーザ射出部である。
【００２５】
本実施形態では、アウタレンズ２は、その外周縁部のやや内側に沿って一体的に形成される透明環状リブ３を有して構成されており、ハウジング４は、環状リブ３の内側に対応する部位に一体的に形成される立壁７を有して構成されている。このとき透明環状リブ３は、アウタレンズ２の全周に亘って形成されており、立壁７は、インナシート２０の外周縁部の全周に対応して設ける必然性はなく、インナシート２０の安定した張設状態が維持できる場合は、インナシート２０の外周縁部に沿って部分的に設けてもよい。
【００２６】
具体的には、アウタレンズ２は、素通しレンズであり、アクリル樹脂（ＰＭＭＡ）やポリカーボネート樹脂（ＰＣ）等の透明な熱可塑性樹脂材で形成されている。
【００２７】
また、ハウジング４は、レーザ光１３に対して吸収性のある熱可塑性樹脂材で構成される。このような熱可塑性樹脂材としては、レーザ光１３に対して吸収性を有する着色料で着色された熱可塑性樹脂材がある。このときの着色料は、例えばカーボンブラックであり、樹脂材は、アウタレンズ２の樹脂材（ＰＭＭＡ、ＰＣ等）との相溶性のある樹脂材が選択される。このような樹脂材としては、例えばＡＢＳ樹脂、アクリロニトリル・エチレンプロピレン・スチレン樹脂（ＡＥＳ）、アクリル・アクリロニトリル・スチレン樹脂（ＡＡＳ（またはＡＳＡ））、アクリロニトリル・スチレン樹脂（ＡＳ）、ＰＣ樹脂、およびポリマーアロイがある。ポリマーアロイは、例えばＰＣ／ＡＢＳ樹脂、ＰＣ／ＡＡＳ樹脂、ＰＣ／ポリブチレンテレフタレート（ＰＢＴ）樹脂、ＰＣ／ポリエチレンテレフタレート（ＰＥＴ）樹脂等、あるいはＰＭＭＡ／ＡＢＳ樹脂、ＰＭＭＡ／ＡＡＳ樹脂、ＰＭＭＡ／ＰＢＴ樹脂、ＰＭＭＡ／ＰＥＴ樹脂等がある。ハウジング４は、前記以外の成分、例えばガラス、シリカ、タルク、炭酸カルシウム等の無機または有機物よりなるフィラー、帯電防止剤、耐侯安定剤等の慣用の添加物の１種以上を樹脂材中に含有させることもできる。
【００２８】
また、インナシート２０は、例えば厚さ０．３〜０．５ｍｍのＰＣ樹脂フィルムで構成される。
【００２９】
また、レーザ光１３は、アウタレンズ２（環状リブ３を含む）内の透過率が充分高くなるような波長を有するものが適宜選択される。このようなレーザ光１３として、半導体レーザ（波長８０８ｎｍ、または９４０ｎｍ）がある。
【００３０】
そして、レーザ溶着は、図１に示すように、透明環状リブ３の先端面を立壁７の外側のハウジング４の平坦面に当接させてアウタレンズ２をセットし、かつアウタレンズ２の裏面と立壁７の先端面との間で挟持するようにしてインナシート２０をセットし、その後前記当接部位を加圧しながら該当個所にアウタレンズ２側からレーザ光１３を照射することにより行う。すなわち、アウタレンズ２のレーザ溶着は、透明環状リブ３の真上にレーザ射出部８を位置させて行われ、インナシート２０のレーザ溶着は、立壁７の真上にレーザ射出部８を移動させて行われる。
【００３１】
アウタレンズ２は、レーザ光１３に対して透明な熱可塑性樹脂材で構成されているので、アウタレンズ２側から照射されるレーザ光１３はアウタレンズ２（透明環状リブ３を含む）を透過してハウジング４に到達する。ハウジング４は、レーザ光１３に対して吸収性のある熱可塑性樹脂材で構成されているので、ハウジング４に到達したレーザ光１３はハウジング４に吸収されて熱に変換され、この熱でハウジング４の照射部位を溶解させる。この溶解熱は透明環状リブ３側にも伝播され、透明環状リブ３を同様に溶解させる。しかして、透明環状リブ３とハウジング４は、その溶解部同士が融合するレーザ溶着により接合される。アウタレンズ２は、このようなレーザ溶着を透明環状リブ３の全周に亘って施すことによって、ハウジング４の開口部を覆うようにして固定される。
【００３２】
また、インナシート２０は、レーザ光１３に対して透明な熱可塑性樹脂材で構成されているので、アウタレンズ２側から照射されるレーザ光１３は、アウタレンズ２およびインナシート２０を透過して立壁７に到達する。立壁７に到達したレーザ光１３は、前述したように立壁７に吸収されて熱に変換され、この熱で立壁７の照射部位を溶解させる。この溶解熱はインナシート２０側にも伝播され、インナシート２０を同様に溶解させる。しかして、インナシート２０と立壁７は、その溶解部同士が融合するレーザ溶着により接合される。
【００３３】
しかして、アウタレンズ２は、アウタレンズ２側から照射されるレーザ光１３による透明環状リブ３とハウジング４との間のレーザ溶着（溶着面９ａ）により固定されている。インナシート２０は、アウタレンズ２の裏面と立壁７の先端面との間に挟持された状態で、アウタレンズ２側から照射されるレーザ光１３によるインナシート２０と立壁７との間のレーザ溶着（溶着面９ｂ）により固定されている。
【００３４】
このように車両用灯具１においては、その溶着面９ａ、９ｂは、振動溶着や接着剤を用いることなく溶解部同士の融合により形成されるので、溶着バリや糸引きや白化を生じさせることなく形成することができる。
【００３５】
このため車両用灯具１は、アウタレンズ２およびインナシート２０のハウジング４への固定が、溶着バリや糸引き並びに白化に起因する外観上の品質の低下を伴うことなく比較的簡単なレーザ溶着作業で確実に行うことができ、ひいてはコストの低減化をも可能としている。
【００３６】
図２は、本発明の第２実施形態としての車両用灯具１０を示す。この車両用灯具１０は、インナシート２０の挟持と、アウタレンズ２とハウジング４の固定とを１個の環状リブを介して行っている点が相違するだけで、他の構成は車両用灯具１と同様に構成されている。
【００３７】
すなわち本実施形態では、ハウジング４は、アウタレンズ２へ突出する不透明環状リブ１４を一体に形成して構成されており、かつ不透明環状リブ１４は、その幅方向の外側に位置するアウタレンズ２へ当接する第１当接面１７ａと、その幅方向の内側に位置するインナシート２０へ当接する第２当接面１７ｂとからなる段部１７を先端面に形成して構成されている。不透明環状リブ１４は、ハウジング４の外周縁部のやや内側の全周に亘って形成されており、かつ第１当接面１７ａは、不透明環状リブ１４の全長に亘って形成される。第２当接面１７ｂは、不透明環状リブ１４の全長に亘って形成しても良いが、インナシート２０の安定した張設状態が維持できる場合は、不透明環状リブ１４に沿って部分的に設けることもできる。アウタレンズ２は、リブを備えない板状体として構成される。
【００３８】
そして、アウタレンズ２およびインナシート２０は、図２に示すように、第１当接面１７ａをアウタレンズ２の裏面に当接させると共に、第２当接面１７ｂとアウタレンズ２との間にインナシート２０を挟持させた状態で、アウタレンズ２側から照射されるレーザ光１３によるレーザ溶着によりハウジング４に固定されている。このときのレーザ溶着もまた、前述したと同様の原理に基づいて行われる。
【００３９】
しかして、アウタレンズ２は、アウタレンズ２を透して照射されるレーザ光１３による第１当接面１７ａへのレーザ溶着（溶着面９ｃ）により固定されており、インナシート２０は、アウタレンズ２およびインナシート２０を透して照射されるレーザ光１３による第２当接面１７ｂへのレーザ溶着（溶着面９ｄ）により固定されている。
【００４０】
このときのレーザ溶着は、第１および第２当接面１７ａおよび１７ｂにそれぞれ照射される各レーザ光１３による個別溶着方法により行うこともできるが、インナシート２０の厚みが薄い（第２当接面１７ｂの深さが浅い）ので、図２に示すように、レーザ光１３を第１当接面１７ａと第２当接面１７ｂに跨る集光径を有して照射することにより、アウタレンズ２およびインナシート２０を、レーザ光１３の同一集光径内で同時に溶着する同時溶着方法を採用することができる。この同時溶着方法は、個別溶着方法と相違して第１当接面１７ａと第２当接面１７ｂとの間でレーザ射出部８が移動することがないので、制御が簡単で良好な溶着操作性を有すると共に、１回の溶着で２箇所を同時に溶着することができるので、溶着工程の簡略化を図ることができる。
【００４１】
このようにして構成される車両用灯具１０は、前述した車両用灯具１と同様な作用効果を奏することができることは勿論のこと、加えて同時溶着方法の採用により製造の容易化とコストの一層の低減化を図ることができる。
【００４２】
図３〜図５は、光透過部材としてインナレンズ２１を採用した車両用灯具２２、２３、２４、２５を示す。これらの車両用灯具２２、２３、２４、２５において、インナレンズ２１は、アウタレンズ２とハウジング４とで区画形成される灯室１１内に設けられている。インナレンズ２１は、例えば、厚さ１．０〜２．０ｍｍのＰＣ樹脂板材、あるいは厚さ１．５〜２．５ｍｍのＰＭＭＡ樹脂板材で構成される。アウタレンズ２とハウジング４は、第１実施形態と同様の樹脂材を用いて構成されている。
【００４３】
車両用灯具２２は、前述した第１実施形態に属するもので、図３に示すように、インナレンズ２１を採用している点が相違するのみで、他の構成およびレーザ溶着の方法は車両用灯具１と同様である。
【００４４】
すなわち、車両用灯具２２は、アウタレンズ２が、アウタレンズ２側から照射されるレーザ光１３による透明環状リブ３とハウジング４との間のレーザ溶着（溶着面９ａ）により固定されており、インナレンズ２１が、アウタレンズ２の裏面と立壁７の先端面との間に挟持された状態で、アウタレンズ２側から照射されるレーザ光１３によるインナレンズ２１と立壁７との間のレーザ溶着（溶着面９ｅ）により固定されており、車両用灯具１と同様の作用効果を奏することができる。
【００４５】
また、車両用灯具２３、２４は、前述した第２実施形態に属するものである。
【００４６】
車両用灯具２３は、図４（ａ）に示すように、不透明環状リブ１４の先端面に厚いインナレンズ２１を受け入れ可能な深い段部１８を形成した点および段部１８の各当接面１８ａ、１８ｂ毎にレーザ溶着する点が相違するだけで、他の構成は車両用灯具１０と同様に構成されている。段部１８は、アウタレンズ２の裏面に当接する第１当接面１８ａと、インナレンズ２１をアウタレンズ２との間で挟持できるようにインナレンズ２１の厚さに相当する深さ（第１当接面１８ａからの段差）に形成される第２当接面１８ｂとから構成されている。
【００４７】
そして、車両用灯具２３は、アウタレンズ２が、アウタレンズ２を透過して照射されるレーザ光１３による段部１８の第１当接面１８ａへのレーザ溶着（溶着面９ｃ）により固定されており、インナレンズ２１が、アウタレンズ２の裏面と段部１８の第２当接面１８ｂとの間に挟持された状態で、アウタレンズ２およびインナレンズ２１を透過して照射されるレーザ光１３による第２当接面１８ｂへのレーザ溶着（溶着面９ｆ）により固定されている。
【００４８】
この車両用灯具２３の場合、第１当接面１８ａと第２当接面１８ｂとの段差が大きいので、レーザ光１３の同一集光径内でのアウタレンズ２およびインナレンズ２１の同時溶着が不能であるが、第１および第２当接面１８ａおよび１８ｂが不透明環状リブ１４の同じ先端面に形成されるものであるから両者の物理的距離は必然的に近くなり、その分レーザ溶着時の各当接面１８ａ、１８ｂ間のレーザ射出部８の移動量が、例えば車両用灯具２２と比較して小さくなり、ひいてはレーザ溶着時の制御が簡単になる。
【００４９】
このため車両用灯具２３は、車両用灯具１０と略同様の作用効果を奏することができる。
【００５０】
車両用灯具２４は、図４（ｂ）に示すように、インナレンズ２１の被挟持部２１ａを一般部よりも肉薄に形成した点およびレーザ光１３の同一集光径内でアウタレンズ２およびインナレンズ２１を同時溶着した点が相違するだけで、他の構成は車両用灯具２３と同様に構成されている。この車両用灯具２４の段部１７は、車両用灯具１０と同様に、アウタレンズ２へ当接する第１当接面１７ａと、被挟持部２１ａへ当接する第２当接面１７ｂとを有して不透明環状リブ１４の先端面に形成されている。
【００５１】
そしてこの車両用灯具２４においては、アウタレンズ２は、アウタレンズ２を透して照射されるレーザ光１３による第１当接面１７ａへのレーザ溶着（溶着面９ｃ）により固定されており、インナレンズ２１は、アウタレンズ２および被挟持部２１ａを透して照射されるレーザ光１３による被挟持部２１ａの第２当接面１７ｂへのレーザ溶着（溶着面９ｇ）により固定されている。その上、溶着面９ｃおよび９ｇは、同時溶着の採用により１回のレーザ溶着により同時に形成することができる。
【００５２】
このため車両用灯具２４は、車両用灯具１０と同様の作用効果を奏することができる。
【００５３】
図５は、第３実施形態としての車両用灯具２５を示す。この車両用灯具２５では、アウタレンズ２は、ハウジング４へ突出する透明環状リブ３を一体に形成して構成されており、かつ透明環状リブ３は、その幅方向の外側に位置するハウジング４へ当接する第１当接面１９ａと、その幅方向の内側に位置するインナレンズ２１へ当接する第２当接面１９ｂとからなる段部１９を先端面に形成して構成されている。第２当接面１９ｂは、透明環状リブ３の全長に亘って形成しても良いが、インナレンズ２１の安定した架設状態が維持できる場合は、透明環状リブ３に沿って部分的に設けることもできる。
【００５４】
そして、アウタレンズ２およびインナレンズ２１は、図５に示すように、第１当接面１９ａをハウジング４の平坦面に当接させると共に、第２当接面１９ｂとハウジング４の平坦面との間にインナレンズ２１を挟持させた状態で、アウタレンズ２側から照射されるレーザ光１３によるレーザ溶着によりハウジング４に固定されている。
【００５５】
しかして、アウタレンズ２は、アウタレンズ２（透明環状リブ３を含む）を透して照射されるレーザ光１３による第１当接面１９ａのハウジング４へのレーザ溶着（溶着面９ｈ）により固定されており、インナレンズ２１は、アウタレンズ２（透明環状リブ３を含む）およびインナレンズ２１を透して照射されるレーザ光１３によるハウジング４へのレーザ溶着（溶着面９ｉ）により固定されている。
【００５６】
このときのレーザ溶着は、溶着面９ｈ、９ｉ毎の個別溶着方法により行うこともできるが、溶着面９ｈ、９ｉがハウジング４の平坦面に形成されるので、図５に示すように、レーザ光１３を溶着面９ｈと溶着面９ｉに跨る集光径を有して照射することにより、レーザ光１３の同一集光径内でアウタレンズ２およびインナレンズ２１を同時に溶着する同時溶着方法を採用することができる。この同時溶着方法は、前述した同時溶着方法と同様に、個別溶着方法と相違して溶着面９ｈと溶着面９ｉとの間でレーザ射出部８が移動することがないので、制御が簡単で良好な溶着操作性を有すると共に、１回の溶着で２箇所を同時に溶着することができるので、溶着工程の簡略化を図ることができる。
【００５７】
このようにして構成される車両用灯具２５は、車両用灯具１０と同様な作用効果を奏することができる。
【００５８】
【発明の効果】
以上詳細に説明したように本発明によれば次の効果を奏することができる。
【００５９】
すなわち、請求項１の発明によれば、アウタレンズおよび光透過部材のハウジングへの固定が、溶着バリや糸引き並びに白化に起因する外観上の品質の低下を伴うことなく比較的簡単なレーザ溶着作業で確実に行うことができ、ひいてはコストの低減化をも可能とする車両用灯具を提供することができる。
【００６０】
また、請求項２の発明によれば、アウタレンズおよび光透過部材が当接する第１および第２当接面を備えた段部を、アウタレンズあるいはハウジングに突出形成される環状リブの先端面に形成したので、アウタレンズおよび光透過部材の各溶着箇所が漸近し、その分溶着箇所間のレーザ光の移動量が少なくなり、これにより請求項１の発明の効果に加えて、溶着作業の制御が簡単で作業精度の向上を図ることができると共に、コストの一層の低減化をも図ることができる。
【００６１】
また、請求項３の発明によれば、レーザ溶着は、レーザ光の第１および第２当接面に跨る同一集光径内でのアウタレンズおよび光透過部材の同時溶着が可能となるので、請求項２の発明の効果に加えて、溶着作業の制御が一層簡単でコストの一層の低減化を図ることができる。
【００６２】
また、請求項４の発明によれば、レーザ光の同一集光径内で、アウタレンズおよび光透過部材を同時に溶着するので、制御が簡単で良好な溶着操作性を有すると共に、溶着工程の簡略化を図ることができる車両用灯具のレーザ溶着方法を提供することができる。
【図面の簡単な説明】
【図１】本発明の第１実施形態としての車両用灯具の断面を示す模式図である。
【図２】本発明の第２実施形態としての車両用灯具の一部断面を示す模式図である。
【図３】本発明の第１実施形態としての他の車両用灯具の断面を示す模式図である。
【図４】（ａ）は本発明の第２実施形態としての他の車両用灯具の一部断面を示す模式図、（ｂ）は本発明の第２実施形態としての更に他の車両用灯具の一部断面を示す模式図である。
【図５】本発明の第３実施形態としての車両用灯具の断面を示す模式図である。
【図６】従来の車両用灯具の課題を説明するための断面模式図である。
【図７】（ａ）、（ｂ）は、従来の他の車両用灯具の課題を説明するための一部断面模式図である。
【図８】従来のさらに他の車両用灯具の課題を説明するための一部断面模式図である。
【符号の説明】
１，１０，２２，２３，２４，２５ 車両用灯具
２ アウタレンズ
３ 透明環状リブ（環状リブ）
４ ハウジング
９ａ〜９ｉ 溶着面（レーザ溶着）
１１ 灯室
１２ 光源バルブ
１３ レーザ光
１４ 不透明環状リブ（環状リブ）
２０ インナシート（光透過部材）
２１ インナレンズ（光透過部材）
２１ａ 被挟持部（インナレンズの）[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a vehicular lamp provided with a light transmitting member such as an inner sheet (film) or an inner lens, which is applied as a rear lamp, for example, in a lamp chamber and a laser welding method thereof.
[0002]
[Prior art]
In the vehicular lamp, the outer lens is made of a transparent thermoplastic resin material, and is fixed so as to cover the opening of the housing so as to define a lamp chamber in cooperation with the housing.
[0003]
Also, the inner sheet (film) is provided close to the back surface of the outer lens for the purpose of improving the appearance, and the inner lens is provided behind the outer lens for the purpose of light distribution control and coloring of the lamp. Yes.
[0004]
As a means for fixing the outer lens to the housing, welding represented by vibration welding, ultrasonic welding, etc. can be joined in a short time, and metal parts such as adhesives and screws are not used. It is becoming mainstream because it does not cause problems such as weight increase and environmental pollution. FIG. 6 shows a state in which the outer lens 2 is fixed to the housing 4.
[0005]
Moreover, the inner sheet | seat 20 is affixed on the back surface side of the outer lens 2 via the double-sided tape 15, as shown in FIG. That is, the inner sheet 20 is affixed via a double-sided tape 15 that is directly affixed to the back surface of the outer lens 2 (FIG. 7A), or a double-sided tape 15 that is affixed to the annular rib 3 of the outer lens 2. (FIG. 7B).
[0006]
Further, as shown in FIG. 8, the inner lens 21 is attached by lance engagement with a lance 16 provided on the inner lens 21, and is further fixed with a screw 17 to prevent rattling or disengagement.
[0007]
[Problems to be solved by the invention]
However, as shown in FIG. 6, vibration welding or ultrasonic welding results in welding between the tip of the annular rib 3 of the outer lens 2 and the flat surface of the housing 4, and welding burrs and stringing 5 appear in the vicinity of the welding portion. In addition, there is a problem that this portion T becomes a wide dummy width and can be observed from the surface side of the outer lens 2, and as a result, the quality of the appearance is deteriorated.
[0008]
In addition, the attachment of the inner sheet 20 and the inner lens 21 takes man-hours and, as a result, incurs high costs, and in the construction method using the double-sided tape 15, there is a risk of peeling or whitening due to heat, vibration, or the like after bonding. There is a problem that there is.
[0009]
Therefore, according to the present invention, fixing the outer lens and the light transmitting member (inner sheet or inner lens) to the housing is a relatively simple operation without deteriorating appearance quality due to welding burrs, stringing, and whitening. It is an object of the present invention to provide a vehicular lamp and a laser welding method thereof that can be reliably performed by the above-described method and can also reduce the cost.
[0010]
[Means for Solving the Problems]
In order to achieve the above object, the invention according to claim 1 is that the outer lens is made of a thermoplastic resin material that is transparent to laser light and is made of a thermoplastic resin material that is absorbable to laser light. The light-transmitting member is made of a transparent thermoplastic resin material and is fixed so as to cover the opening of the housing so as to define a light chamber in which a light source bulb is provided in cooperation with the housing. And a vehicle lamp provided in the lamp chamber so as to transmit light from the light source bulb to the outer lens side, wherein the outer lens has a contact portion with an opening of the housing. The outer periphery of the outer lens and the housing are fixed to the housing by laser welding over the entire circumference with laser light irradiated from the side. Grayed and while being held between the, irradiated from at least partially the outer lens side 該挟 lifting site And transmitted through the clamping portion of the outer lens and the light transmitting member. It is fixed to the housing by laser welding with a laser beam.
[0011]
Therefore, in the first aspect of the invention, since the outer lens is made of a thermoplastic resin material that is transparent to the laser beam, the laser beam irradiated from the outer lens side passes through the outer lens and reaches the housing. Since the housing is made of a thermoplastic resin material that absorbs laser light, the laser light that reaches the housing is absorbed by the housing and converted into heat, and this heat dissolves the irradiated portion of the housing. . This heat of dissolution is also propagated to the outer lens side, and the outer lens is similarly dissolved. Thus, the outer lens and the housing are joined by laser welding in which the melted portions are fused. The outer lens is fixed so as to cover the opening of the housing by applying such laser welding over the entire circumference of the outer lens.
[0012]
Further, since the light transmitting member is made of a thermoplastic resin material that is transparent to the laser light, the laser light irradiated from the outer lens side passes through the outer lens and the light transmitting member and reaches the housing. As described above, the laser light that has reached the housing is absorbed by the housing and converted into heat, and the irradiated portion of the housing is dissolved by this heat. This heat of dissolution is also propagated to the light transmitting member side, and the light transmitting member is similarly dissolved. Thus, the light transmitting member and the housing are joined by laser welding in which the melted portions are fused. Since the light transmitting member is not required to have a sealing property on the welding surface, it is sufficient that such laser welding is partially applied.
[0013]
Moreover, since the welding surface is formed by the fusion of the melting parts, it can be formed without causing welding burrs or stringing.
[0014]
Moreover, invention of Claim 2 is a vehicle lamp of Claim 1, Comprising:
Any one member of the outer lens and the housing is formed by integrally forming an annular rib protruding to the other member, and
The annular rib includes a first contact surface that contacts the other member positioned on the outer side in the width direction and a second contact surface that contacts the light transmitting member positioned on the inner side in the width direction. It is formed by forming a step on the tip surface,
The outer lens and the light transmissive member abut the first abutting surface against the other member, and the light transmissive member is sandwiched between the second abutting surface and the other member. It is fixed to the housing by laser welding with laser light emitted from the outer lens side.
[0015]
For this reason, in the invention of claim 2, the annular rib is made of a thermoplastic resin material that is transparent to the laser beam when formed on the outer lens, and is absorbent to the laser beam when formed on the housing. It is composed of a certain thermoplastic resin material. For this reason, the laser light irradiated from the outer lens side reaches the housing via the annular rib or the annular rib and the light transmitting member in the former case, whereas the laser light is directly or via the light transmitting member in the latter case. Reach the rib step.
[0016]
In the former case, the welding surface is formed between the first contact surface of the step portion and the housing and between the light transmitting member and the housing, whereas in the latter case, the outer lens and the step portion are formed. Between the first contact surface and between the light transmission member and the second contact surface of the stepped portion.
[0017]
In the case of laser welding, when the welding surface of the housing is a flat surface, simultaneous welding of the outer lens and the light transmitting member within the same light collection diameter straddling the first and second contact surfaces of the laser light In contrast, in the latter case, if the light transmitting member is thick, the depth of the second contact surface becomes correspondingly deep and the simultaneous welding becomes impossible. Since the outer lens and the light transmitting member can be welded with a small amount of movement of the laser beam corresponding to the depth (depth of the second contact surface), the control is simple.
[0018]
Moreover, invention of Claim 3 is a vehicle lamp of Claim 2, Comprising:
The annular rib is formed integrally with the housing,
The light transmitting member is configured to have a sandwiched portion formed thinner than a general portion at a peripheral portion, and
The outer lens is fixed by laser welding to the first contact surface by laser light irradiated through the outer lens, and the light transmitting member is a laser irradiated through the outer lens and the sandwiched portion. It is fixed by laser welding to the second contact surface of the sandwiched portion by light.
[0019]
For this reason, in the invention of claim 3, the depth of the second abutting surface is also reduced by the amount of the sandwiched portion formed thin, so that the laser welding is performed with the same light concentration straddling the first and second abutting surfaces of the laser light. The outer lens and the light transmitting member can be welded simultaneously within the diameter.
[0020]
The invention of claim 4 is the laser welding method for a vehicle lamp according to claim 2 or 3,
By irradiating the laser beam with a condensing diameter straddling the first contact surface and the second contact surface, the outer lens and the light transmitting member are simultaneously welded within the same condensing diameter of the laser light. It is characterized by doing.
[0021]
For this reason, in the invention of claim 4, the welding process can be simplified.
[0022]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be specifically described based on embodiments. In addition, the member which has the same function as the member shown in FIGS. 6-8 is attached | subjected and demonstrated with the same code | symbol.
[0023]
FIG. 1 shows a vehicular lamp 1 as a first embodiment of the present invention. The vehicular lamp 1 includes a housing 4 in which an outer lens 2 is made of a thermoplastic resin material that is transparent to the laser light 13 and is made of a thermoplastic resin material that is absorbable to the laser light 13. The inner sheet 20 as a light transmitting member is fixed to the laser beam 13 so as to cover the opening of the housing 4 so as to define the lamp chamber 11 provided with the light source bulb 12 together. It is made of a transparent thermoplastic resin material, and is provided in the lamp chamber 11 so as to transmit the light from the light source bulb 12 to the outer lens 2 side.
[0024]
The outer lens 2 is fixed to the housing 4 by laser welding the entire contact portion of the outer lens 2 with the laser beam 13 irradiated from the outer lens 2 side at the contact portion with the opening of the housing 4, and the inner sheet 20. Is clamped between the outer lens 2 and the housing 4 and is fixed to the housing 4 by at least partially laser welding the clamping portion with a laser beam 13 irradiated from the outer lens 2 side. In FIG. 1, reference numeral 6 is a reflecting surface, and reference numeral 8 is a laser emitting portion.
[0025]
In the present embodiment, the outer lens 2 is configured to have a transparent annular rib 3 that is integrally formed along the inner side of the outer peripheral edge thereof, and the housing 4 corresponds to the inner side of the annular rib 3. It has a standing wall 7 formed integrally with the part. At this time, the transparent annular rib 3 is formed over the entire circumference of the outer lens 2, and the standing wall 7 is not necessarily provided corresponding to the entire circumference of the outer peripheral edge of the inner sheet 20, and the inner sheet 20 is stable. If the tensioned state can be maintained, the inner sheet 20 may be partially provided along the outer peripheral edge.
[0026]
Specifically, the outer lens 2 is a through lens and is formed of a transparent thermoplastic resin material such as acrylic resin (PMMA) or polycarbonate resin (PC).
[0027]
The housing 4 is made of a thermoplastic resin material that is absorbable with respect to the laser beam 13. As such a thermoplastic resin material, there is a thermoplastic resin material colored with a colorant having absorptivity with respect to the laser beam 13. The colorant at this time is, for example, carbon black, and a resin material that is compatible with the resin material (PMMA, PC, etc.) of the outer lens 2 is selected. Examples of such resin materials include ABS resin, acrylonitrile / ethylene propylene / styrene resin (AES), acrylic / acrylonitrile / styrene resin (AAS (or ASA)), acrylonitrile / styrene resin (AS), PC resin, and polymer. There is an alloy. The polymer alloy is, for example, PC / ABS resin, PC / AAS resin, PC / polybutylene terephthalate (PBT) resin, PC / polyethylene terephthalate (PET) resin, or PMMA / ABS resin, PMMA / AAS resin, PMMA / PBT resin. And PMMA / PET resin. The housing 4 contains, in the resin material, one or more of other conventional components such as fillers made of inorganic or organic materials such as glass, silica, talc, calcium carbonate, antistatic agents, anti-waxing stabilizers and the like. It can also be made.
[0028]
Moreover, the inner sheet | seat 20 is comprised with the PC resin film of thickness 0.3-0.5 mm, for example.
[0029]
Further, the laser beam 13 is appropriately selected to have a wavelength such that the transmittance in the outer lens 2 (including the annular rib 3) is sufficiently high. As such a laser beam 13, there is a semiconductor laser (wavelength 808 nm or 940 nm).
[0030]
As shown in FIG. 1, the laser welding is performed by setting the outer lens 2 by bringing the front end surface of the transparent annular rib 3 into contact with the flat surface of the housing 4 outside the standing wall 7, and the back surface of the outer lens 2 and the standing wall 7. The inner sheet 20 is set so as to be sandwiched between the front end surface and the laser beam 13 is irradiated from the outer lens 2 side to the corresponding portion while pressurizing the contact portion. That is, the laser welding of the outer lens 2 is performed by positioning the laser emitting portion 8 directly above the transparent annular rib 3, and the laser welding of the inner sheet 20 is performed by moving the laser emitting portion 8 directly above the standing wall 7. Done.
[0031]
Since the outer lens 2 is made of a thermoplastic resin material that is transparent to the laser beam 13, the laser beam 13 irradiated from the outer lens 2 side passes through the outer lens 2 (including the transparent annular rib 3) and passes through the housing 4. To reach. Since the housing 4 is made of a thermoplastic resin material that absorbs the laser light 13, the laser light 13 that has reached the housing 4 is absorbed by the housing 4 and converted into heat. To dissolve the irradiated part. This heat of dissolution is also propagated to the transparent annular rib 3 side, and the transparent annular rib 3 is similarly dissolved. Thus, the transparent annular rib 3 and the housing 4 are joined by laser welding in which the melted portions are fused. The outer lens 2 is fixed so as to cover the opening of the housing 4 by performing such laser welding over the entire circumference of the transparent annular rib 3.
[0032]
Further, since the inner sheet 20 is made of a thermoplastic resin material that is transparent to the laser light 13, the laser light 13 irradiated from the outer lens 2 side passes through the outer lens 2 and the inner sheet 20 and passes through the standing wall 7. To reach. The laser beam 13 that has reached the standing wall 7 is absorbed by the standing wall 7 and converted into heat as described above, and the irradiation site of the standing wall 7 is dissolved by this heat. This heat of dissolution is also propagated to the inner sheet 20 side, and the inner sheet 20 is similarly dissolved. Thus, the inner sheet 20 and the standing wall 7 are joined by laser welding in which the melted portions are fused.
[0033]
Thus, the outer lens 2 is fixed by laser welding (welding surface 9a) between the transparent annular rib 3 and the housing 4 by the laser beam 13 irradiated from the outer lens 2 side. The inner sheet 20 is sandwiched between the back surface of the outer lens 2 and the front end surface of the standing wall 7, and laser welding (welding) between the inner sheet 20 and the standing wall 7 by the laser light 13 irradiated from the outer lens 2 side. It is fixed by the surface 9b).
[0034]
As described above, in the vehicular lamp 1, the welding surfaces 9a and 9b are formed by fusion of the melted parts without using vibration welding or an adhesive, so that welding burrs, stringing or whitening does not occur. Can be formed.
[0035]
For this reason, in the vehicular lamp 1, the outer lens 2 and the inner seat 20 can be fixed to the housing 4 by a relatively simple laser welding operation without deteriorating appearance quality due to welding burrs, stringing, and whitening. This can be performed reliably, and as a result, the cost can be reduced.
[0036]
FIG. 2 shows a vehicular lamp 10 as a second embodiment of the present invention. The vehicular lamp 10 is different from the vehicular lamp 1 only in that the inner seat 20 is clamped and the outer lens 2 and the housing 4 are fixed via one annular rib. It is constituted similarly.
[0037]
That is, in the present embodiment, the housing 4 is configured by integrally forming the opaque annular rib 14 that projects to the outer lens 2, and the opaque annular rib 14 abuts on the outer lens 2 positioned outside in the width direction. A stepped portion 17 comprising a first contact surface 17a and a second contact surface 17b that contacts the inner sheet 20 located inside the width direction is formed on the tip surface. The opaque annular rib 14 is formed over the entire inner circumference of the outer peripheral edge of the housing 4, and the first contact surface 17 a is formed over the entire length of the opaque annular rib 14. The second contact surface 17 b may be formed over the entire length of the opaque annular rib 14, but is provided partially along the opaque annular rib 14 when the inner sheet 20 can be stably stretched. You can also The outer lens 2 is configured as a plate-like body that does not include a rib.
[0038]
As shown in FIG. 2, the outer lens 2 and the inner sheet 20 bring the first contact surface 17 a into contact with the back surface of the outer lens 2 and the inner sheet 20 between the second contact surface 17 b and the outer lens 2. Is fixed to the housing 4 by laser welding with a laser beam 13 irradiated from the outer lens 2 side. Laser welding at this time is also performed based on the same principle as described above.
[0039]
Thus, the outer lens 2 is fixed by laser welding (welding surface 9c) to the first contact surface 17a by the laser light 13 irradiated through the outer lens 2, and the inner sheet 20 is fixed to the outer lens 2 and the inner lens 20. The laser beam 13 irradiated through the sheet 20 is fixed by laser welding (welding surface 9d) to the second contact surface 17b.
[0040]
The laser welding at this time can be performed by an individual welding method using the laser beams 13 applied to the first and second contact surfaces 17a and 17b, respectively, but the inner sheet 20 is thin (second contact). As shown in FIG. 2, the outer lens 2 is irradiated by irradiating the laser beam 13 with a condensed diameter straddling the first contact surface 17a and the second contact surface 17b, as shown in FIG. And the simultaneous welding method which welds the inner sheet | seat 20 simultaneously within the same condensing diameter of the laser beam 13 is employable. In this simultaneous welding method, unlike the individual welding method, the laser emitting portion 8 does not move between the first contact surface 17a and the second contact surface 17b, so that the control operation is simple and good. In addition, the welding process can be simplified because two places can be welded simultaneously by one welding.
[0041]
The vehicular lamp 10 configured as described above can achieve the same effects as the vehicular lamp 1 described above, and in addition, the simultaneous welding method can be used to facilitate manufacture and further increase the cost. Can be reduced.
[0042]
3 to 5 show vehicle lamps 22, 23, 24, and 25 that employ an inner lens 21 as a light transmitting member. In these vehicle lamps 22, 23, 24, 25, the inner lens 21 is provided in a lamp chamber 11 that is defined by the outer lens 2 and the housing 4. The inner lens 21 is made of, for example, a PC resin plate having a thickness of 1.0 to 2.0 mm or a PMMA resin plate having a thickness of 1.5 to 2.5 mm. The outer lens 2 and the housing 4 are configured using the same resin material as in the first embodiment.
[0043]
The vehicular lamp 22 belongs to the first embodiment described above, and as shown in FIG. 3, the only difference is that the inner lens 21 is employed. Other configurations and laser welding methods are for the vehicular. This is the same as the lamp 1.
[0044]
That is, in the vehicular lamp 22, the outer lens 2 is fixed by laser welding (welding surface 9a) between the transparent annular rib 3 and the housing 4 by the laser beam 13 irradiated from the outer lens 2 side. Is welded between the inner lens 21 and the standing wall 7 by the laser beam 13 irradiated from the outer lens 2 side while being sandwiched between the back surface of the outer lens 2 and the tip surface of the standing wall 7 (welding surface 9e). Therefore, the same effects as the vehicular lamp 1 can be obtained.
[0045]
The vehicle lamps 23 and 24 belong to the second embodiment described above.
[0046]
As shown in FIG. 4A, the vehicular lamp 23 is formed with a deep step portion 18 capable of receiving the thick inner lens 21 on the front end surface of the opaque annular rib 14, and each contact surface 18a of the step portion 18. The other structures are the same as those of the vehicular lamp 10 except that the laser welding is different every 18b. The step portion 18 has a depth corresponding to the thickness of the inner lens 21 (first contact) so that the inner lens 21 can be clamped between the first contact surface 18 a that contacts the back surface of the outer lens 2 and the outer lens 2. And a second contact surface 18b formed at a step from the surface 18a.
[0047]
In the vehicular lamp 23, the outer lens 2 is fixed by laser welding (welding surface 9c) to the first contact surface 18a of the step portion 18 by the laser light 13 that is transmitted through the outer lens 2 and irradiated. In a state where the inner lens 21 is sandwiched between the back surface of the outer lens 2 and the second contact surface 18 b of the step portion 18, the second contact by the laser light 13 that is transmitted through and irradiated through the outer lens 2 and the inner lens 21. It is fixed by laser welding (welding surface 9f) to the contact surface 18b.
[0048]
In the case of this vehicular lamp 23, since the step between the first contact surface 18a and the second contact surface 18b is large, simultaneous welding of the outer lens 2 and the inner lens 21 within the same condensing diameter of the laser beam 13 is impossible. However, since the first and second abutment surfaces 18a and 18b are formed on the same tip surface of the opaque annular rib 14, the physical distance between the two becomes inevitably close, and accordingly, at the time of laser welding. The amount of movement of the laser emitting portion 8 between the contact surfaces 18a and 18b is smaller than that of the vehicular lamp 22, for example, and control during laser welding is simplified.
[0049]
For this reason, the vehicular lamp 23 can achieve substantially the same operational effects as the vehicular lamp 10.
[0050]
As shown in FIG. 4B, the vehicular lamp 24 includes the outer lens 2 and the inner lens within the same condensing diameter of the laser light 13 and the point that the sandwiched portion 21a of the inner lens 21 is formed thinner than the general portion. The other structure is the same as that of the vehicular lamp 23 except that 21 is simultaneously welded. The step portion 17 of the vehicular lamp 24 has a first abutment surface 17a that abuts against the outer lens 2 and a second abutment surface 17b that abuts against the sandwiched portion 21a, as in the vehicular lamp 10. The opaque annular rib 14 is formed on the front end surface.
[0051]
In this vehicular lamp 24, the outer lens 2 is fixed by laser welding (welding surface 9c) to the first contact surface 17a by the laser light 13 irradiated through the outer lens 2, and the inner lens 21 Is fixed by laser welding (welding surface 9g) to the second abutting surface 17b of the sandwiched portion 21a by the laser light 13 irradiated through the outer lens 2 and the sandwiched portion 21a. In addition, the welding surfaces 9c and 9g can be simultaneously formed by one laser welding by adopting simultaneous welding.
[0052]
For this reason, the vehicular lamp 24 can achieve the same effects as the vehicular lamp 10.
[0053]
FIG. 5 shows a vehicular lamp 25 as a third embodiment. In this vehicular lamp 25, the outer lens 2 is formed by integrally forming a transparent annular rib 3 projecting to the housing 4, and the transparent annular rib 3 contacts the housing 4 positioned on the outer side in the width direction. A stepped portion 19 comprising a first contact surface 19a in contact and a second contact surface 19b in contact with the inner lens 21 located on the inner side in the width direction is formed on the tip surface. The second contact surface 19 b may be formed over the entire length of the transparent annular rib 3, but when the inner lens 21 can maintain a stable erected state, it is partially provided along the transparent annular rib 3. You can also.
[0054]
As shown in FIG. 5, the outer lens 2 and the inner lens 21 bring the first contact surface 19 a into contact with the flat surface of the housing 4, and between the second contact surface 19 b and the flat surface of the housing 4. In the state where the inner lens 21 is held between the outer lens 2 and the outer lens 2, it is fixed to the housing 4 by laser welding with the laser beam 13 irradiated from the outer lens 2 side.
[0055]
Thus, the outer lens 2 is fixed by laser welding (welding surface 9h) of the first contact surface 19a to the housing 4 by the laser light 13 irradiated through the outer lens 2 (including the transparent annular rib 3). The inner lens 21 is fixed by laser welding (welding surface 9i) to the housing 4 by laser light 13 irradiated through the outer lens 2 (including the transparent annular rib 3) and the inner lens 21.
[0056]
The laser welding at this time can be performed by an individual welding method for each of the welding surfaces 9h and 9i. However, since the welding surfaces 9h and 9i are formed on the flat surface of the housing 4, as shown in FIG. By adopting a simultaneous welding method in which the outer lens 2 and the inner lens 21 are simultaneously welded within the same condensing diameter of the laser beam 13 by irradiating 13 with a condensing diameter straddling the welding surface 9h and the welding surface 9i. Can do. This simultaneous welding method is similar to the above-described simultaneous welding method, and unlike the individual welding method, since the laser emitting portion 8 does not move between the welding surface 9h and the welding surface 9i, the control is simple and good. In addition to having excellent welding operability, two places can be welded simultaneously by one welding, so that the welding process can be simplified.
[0057]
The vehicular lamp 25 configured as described above can achieve the same effects as the vehicular lamp 10.
[0058]
【The invention's effect】
As described above in detail, according to the present invention, the following effects can be obtained.
[0059]
That is, according to the first aspect of the present invention, the fixing of the outer lens and the light transmitting member to the housing is a relatively simple laser welding operation without accompanying deterioration in quality due to welding burr, stringing, and whitening. Therefore, it is possible to provide a vehicular lamp that can be surely performed and that can also reduce the cost.
[0060]
According to the second aspect of the present invention, the step portion having the first and second contact surfaces with which the outer lens and the light transmitting member are in contact is formed on the front end surface of the annular rib protruding from the outer lens or the housing. Therefore, the welding locations of the outer lens and the light transmitting member are asymptotically moved, and the amount of movement of the laser light between the welding locations is reduced accordingly. The work accuracy can be improved and the cost can be further reduced.
[0061]
Further, according to the invention of claim 3, laser welding enables simultaneous welding of the outer lens and the light transmitting member within the same condensing diameter straddling the first and second contact surfaces of the laser light. In addition to the effect of the invention of item 2, the welding operation can be controlled more easily and the cost can be further reduced.
[0062]
According to the invention of claim 4, since the outer lens and the light transmitting member are welded at the same time within the same condensing diameter of the laser beam, the control is simple and the welding process is easy and the welding process is simplified. Thus, it is possible to provide a laser welding method for a vehicular lamp.
[Brief description of the drawings]
FIG. 1 is a schematic view showing a cross section of a vehicular lamp as a first embodiment of the present invention.
FIG. 2 is a schematic view showing a partial cross section of a vehicular lamp as a second embodiment of the present invention.
FIG. 3 is a schematic view showing a cross section of another vehicular lamp as the first embodiment of the present invention.
4A is a schematic diagram showing a partial cross section of another vehicular lamp as a second embodiment of the present invention, and FIG. 4B is still another vehicular lamp as a second embodiment of the present invention. It is a schematic diagram which shows a partial cross section.
FIG. 5 is a schematic view showing a cross section of a vehicular lamp as a third embodiment of the present invention.
FIG. 6 is a schematic cross-sectional view for explaining a problem of a conventional vehicular lamp.
FIGS. 7A and 7B are schematic partial cross-sectional views for explaining problems of another conventional vehicular lamp. FIGS.
FIG. 8 is a partial cross-sectional schematic diagram for explaining a problem of still another conventional vehicular lamp.
[Explanation of symbols]
1, 10, 22, 23, 24, 25 Vehicle lamp
2 Outer lens
3 Transparent annular rib (annular rib)
4 Housing
9a to 9i welding surface (laser welding)
11 Light room
12 Light source bulb
13 Laser light
14 Opaque annular rib (annular rib)
20 Inner sheet (light transmission member)
21 Inner lens (light transmission member)
21a Clamped part (inner lens)

Claims (4)

アウタレンズが、レーザ光に対して透明な熱可塑性樹脂材で構成されると共に、レーザ光に対して吸収性のある熱可塑性樹脂材で構成されたハウジングと共働して光源バルブの設けられる灯室を画成するように前記ハウジングの開口部を覆うようにして固定されており、かつ光透過部材が、レーザ光に対して透明な熱可塑性樹脂材で構成されると共に、前記光源バルブの光を前記アウタレンズ側に透過するように前記灯室内に設けられている車両用灯具であって、
前記アウタレンズは、前記ハウジングの開口部との当接部位を前記アウタレンズ側から照射されるレーザ光により全周に亘ってレーザ溶着することにより前記ハウジングに固定されており、かつ前記光透過部材は、前記アウタレンズと前記ハウジングとの間に挟持されると共に、該挟持部位を少なくとも部分的に前記アウタレンズ側から照射されてアウタレンズおよび光透過部材の該挟持部位を透過したレーザ光によりレーザ溶着することにより前記ハウジングに固定されていることを特徴とする車両用灯具。A lamp chamber in which the outer lens is made of a thermoplastic resin material that is transparent to laser light and is provided with a light source bulb in cooperation with a housing that is made of a thermoplastic resin material that absorbs laser light. The light transmitting member is made of a thermoplastic resin material that is transparent to the laser light and covers the opening of the housing so as to define the light. A vehicular lamp provided in the lamp chamber so as to transmit to the outer lens side,
The outer lens is fixed to the housing by laser welding a laser beam irradiated from the outer lens side to a contact portion with the opening of the housing, and the light transmitting member is The laser beam is sandwiched between the outer lens and the housing, and is laser-welded by a laser beam that is irradiated at least partially from the outer lens side of the clamping portion and transmitted through the clamping portion of the outer lens and the light transmitting member. A vehicular lamp characterized by being fixed to a housing. 請求項１に記載の車両用灯具であって、
前記アウタレンズおよびハウジングのいずれか一方の部材は、他方の部材へ突出する環状リブを一体に形成して構成されており、かつ
前記環状リブは、その幅方向の外側に位置する前記他方の部材へ当接する第１当接面と、その幅方向の内側に位置する前記光透過部材へ当接する第２当接面とからなる段部を先端面に形成して構成されており、
前記アウタレンズおよび光透過部材は、前記第１当接面を前記他方の部材へ当接させると共に、前記第２当接面と他方の部材との間に前記光透過部材を挟持させた状態で、前記アウタレンズ側から照射されるレーザ光によるレーザ溶着により前記ハウジングに固定されていることを特徴とする車両用灯具。The vehicular lamp according to claim 1,
Any one member of the outer lens and the housing is formed by integrally forming an annular rib protruding to the other member, and the annular rib is connected to the other member located outside in the width direction. A stepped portion comprising a first abutting surface that abuts and a second abutting surface that abuts against the light transmitting member located on the inner side in the width direction is formed on the distal end surface;
The outer lens and the light transmissive member abut the first abutting surface against the other member, and the light transmissive member is sandwiched between the second abutting surface and the other member. A vehicular lamp characterized by being fixed to the housing by laser welding with laser light irradiated from the outer lens side. 請求項２に記載の車両用灯具であって、
前記環状リブは、前記ハウジングに一体に形成されており、
前記光透過部材は、一般部よりも肉薄に形成される被挟持部を周縁部に有して構成されており、かつ
前記アウタレンズは、アウタレンズを透して照射されるレーザ光による第１当接面へのレーザ溶着により固定されると共に、前記光透過部材は、アウタレンズおよび前記被挟持部を透して照射されるレーザ光による前記被挟持部の第２当接面へのレーザ溶着により固定されていることを特徴とする車両用灯具。The vehicular lamp according to claim 2,
The annular rib is formed integrally with the housing,
The light transmitting member is configured to have a sandwiched portion formed thinner than a general portion at a peripheral portion, and the outer lens is a first contact by a laser beam irradiated through the outer lens. The light transmitting member is fixed by laser welding to the second contact surface of the sandwiched portion by laser light irradiated through the outer lens and the sandwiched portion. A vehicular lamp characterized by the above. 請求項２または３に記載の車両用灯具のレーザ溶着方法であって、
前記レーザ光を前記第１当接面と第２当接面に跨る集光径を有して照射することにより、前記アウタレンズおよび光透過部材を、前記レーザ光の同一集光径内で同時に溶着することを特徴とする車両用灯具のレーザ溶着方法。A method for laser welding a vehicle lamp according to claim 2 or 3,
By irradiating the laser beam with a condensing diameter straddling the first contact surface and the second contact surface, the outer lens and the light transmitting member are simultaneously welded within the same condensing diameter of the laser light. A laser welding method for a vehicular lamp characterized by comprising:
JP2001311304A 2001-10-09 2001-10-09 Vehicle lamp and laser welding method thereof Expired - Fee Related JP3972621B2 (en)

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