JP2010153113A - Method for manufacturing lamp for vehicle, lens of vehicle lamp, and sheet member for lens forming of vehicle lamp - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a lamp for vehicle in which the lamp functional color of a multi-color lens which is formed by vacuum forming of a film-like sheet member is made to present nearly uniform color, a lens for vehicle lamp, and a sheet member for forming a lens for vehicle lamp. <P>SOLUTION: This is the method of manufacturing a lens 50 for vehicle lamp 20 by vacuum forming of a film-like sheet member 52 on which a lamp functional color R is printed by vacuum forming dies 60. A deep color portion Rd which is deeper than the other portion is provided in the lamp functional color R, and by applying a vacuum forming, the sheet member 52 is expanded and the deep color portion Rd is expanded to become a light color, and the lamp functional color R is made to present nearly uniform color. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a vehicular lamp such as a rear combination lamp having a multicolor lens, a lens for the vehicular lamp, and a lens forming sheet member for the vehicular lamp.

In a vehicular lamp such as a rear combination lamp, in which a plurality of lamp chambers containing light sources are arranged, and each lamp chamber is blocked by a multi-colored lens color-coded in the lamp function color of each lamp chamber. A method of forming a multicolor lens by vacuum-drawing a transfer film colored with a functional color and adhering it to a mold and then forming a lens-forming resin material by injection molding has been conventionally known (for example, Patent Document 1).
JP-A-1-303402

  However, since the multicolor lens formed by injection molding is thick, it is not suitable for reducing the weight of the vehicular lamp. Therefore, it was considered to form a thin multicolor lens by vacuum forming a film-like sheet member color-coded in lamp functional colors, and to reduce the weight of the vehicular lamp. Since the sheet-shaped sheet member expands during vacuum forming, there is a problem that a portion that is lighter than the desired color appears in the lamp function color.

  Therefore, in view of the above circumstances, the present invention provides a method for manufacturing a vehicular lamp that can cause the lamp functional color of a multicolor lens formed by vacuum forming a film-like sheet member to exhibit a substantially uniform color, It is an object of the present invention to obtain a lens for the vehicle lamp and a lens forming sheet member for the vehicle lamp.

  In order to achieve the above object, according to the first aspect of the present invention, there is provided a method for manufacturing a vehicular lamp, comprising: vacuum forming a film-like sheet member on which a lamp functional color is printed with a vacuum forming die. A method of manufacturing a lens for a vehicle lamp in which a dark color portion having a darker color than other parts is imparted to the lamp functional color, and the sheet member is stretched by vacuum forming, whereby the dark color portion The lamp function color is reduced so that the lamp functional color exhibits a substantially uniform color.

  According to the first aspect of the present invention, since the dark color portion having a darker color than other portions is given to the lamp function color, the film-like sheet member on which the lamp function color is printed is vacuum-formed. Thus, even if a multicolor lens is formed, the functional color of the lamp can be substantially uniform.

  The vehicle lamp manufacturing method according to claim 2 is the vehicle lamp manufacturing method according to claim 1, wherein the dark color portion is opposed to a bulging portion formed in the vacuum molding die. It is characterized by being placed and vacuum formed.

  According to the second aspect of the present invention, even when a multicolor lens having a curved surface is formed, the functional color of the lamp can be substantially uniform. That is, when a multicolor lens having a curved surface is formed, the curved surface is formed by the bulging portion formed in the vacuum forming mold. Therefore, the sheet member is remarkably stretched at the bulging portion. Therefore, by arranging the dark color portion so as to face the bulging portion, the lamp function color can be made to exhibit a substantially uniform color.

  The vehicle lamp manufacturing method according to claim 3 is the vehicle lamp manufacturing method according to claim 2, in which the dark color portion becomes darker as it goes near a substantially central portion of the bulging portion. It is characterized by being said.

  According to the third aspect of the present invention, the lamp function color can be substantially uniform even in the vicinity of the substantially central portion of the bulging portion where the expansion of the sheet member is most remarkable.

  The method for manufacturing a vehicular lamp according to claim 4 is the method for manufacturing a vehicular lamp according to any one of claims 1 to 3, wherein the density of the dark portion is the sheet member. It is characterized by being gradually changed so as to become lighter as the degree of expansion of is smaller.

  According to the fourth aspect of the present invention, the lamp function color after vacuum forming can exhibit a substantially uniform color.

  A lens for a vehicle lamp according to a fifth aspect of the present invention is manufactured by the method for manufacturing a vehicle lamp according to any one of the first to fourth aspects.

  According to the fifth aspect of the present invention, it is possible to obtain a film-like lens in which the lamp functional color exhibits a substantially uniform color.

  In addition, the lens molding sheet member for a vehicular lamp according to claim 6 of the present invention is formed in a film shape on which a lamp functional color to which a dark portion having a darker color than other portions is given is printed. It is characterized by being.

  According to the sixth aspect of the present invention, since the dark color portion having a darker color than other portions is given to the lamp function color, the film-like sheet member on which the lamp function color is printed is vacuum-formed. Thus, even if a multicolor lens is formed, the functional color of the lamp can be substantially uniform.

  Further, the lens molding sheet member of the vehicle lamp according to claim 7 is opposed to the bulging portion formed in the vacuum molding die in the lens molding sheet member of the vehicle lamp according to claim 6. The site | part to arrange | position is made into the said dark color part, It is characterized by the above-mentioned.

  According to the seventh aspect of the present invention, even when a multicolor lens having a curved surface is formed, the functional color of the lamp can be substantially uniform. That is, when a multicolor lens having a curved surface is formed, the curved surface is formed by the bulging portion formed in the vacuum forming mold. Therefore, the sheet member is remarkably stretched at the bulging portion. Therefore, by arranging the dark color portion so as to face the bulging portion, the lamp function color can be made to exhibit a substantially uniform color.

  Further, the lens molding sheet member of the vehicular lamp according to claim 8 is a deep color as the lens molding sheet member of the vehicular lamp according to claim 7 approaches the substantially central portion of the bulging portion. It is characterized by being said.

  According to the eighth aspect of the present invention, the lamp function color can be substantially uniform even in the vicinity of the substantially central portion of the bulging portion where the extension of the sheet member is most remarkable.

  Further, a lens molding sheet member for a vehicle lamp according to claim 9 is the lens molding sheet member for a vehicle lamp according to any one of claims 6 to 8, wherein It is characterized in that the shade is gradually changed so as to become lighter as the degree of expansion is smaller.

  According to the ninth aspect of the present invention, the lamp function color after vacuum forming can exhibit a substantially uniform color.

  As described above, according to the present invention, a method for manufacturing a vehicular lamp that can cause the lamp functional color of a multicolor lens formed by vacuum forming a film-like sheet member to exhibit a substantially uniform color, and It is possible to provide a lens for the vehicular lamp and a lens forming sheet member for the vehicular lamp.

  DESCRIPTION OF THE PREFERRED EMBODIMENTS The best mode for carrying out the present invention will be described below in detail based on the embodiments shown in the drawings. FIG. 1 is a schematic perspective view showing the rear side of the vehicle body of the vehicle, and FIG. 2 is a schematic side sectional view showing a vehicular lamp (rear combination lamp 20) according to the present embodiment. FIG. 3 is a schematic front view showing a multicolor lens, and FIG. 4 is a schematic side sectional view showing a vacuum forming mold for vacuum forming the multicolor lens.

  5A is a schematic front view and a schematic side view showing a sheet member before vacuum forming, and FIG. 5B is a schematic front view and a schematic side view showing a multicolor lens after vacuum forming. . 6A is a schematic front view and a schematic side view showing the sheet member before vacuum forming according to the comparative example, and FIG. 6B is a schematic showing the multicolor lens after vacuum forming according to the comparative example. It is a front view and a schematic side view. In each drawing, an arrow UP appropriately indicates the vehicle body upward direction, and an arrow FR indicates the vehicle body front direction.

  As shown in FIG. 1, a rear bumper 14 is disposed in the vehicle width direction at the vehicle body rear side end portion of the vehicle 10. A pair of left and right rear combination lamps 20 as an example of a vehicular lamp is disposed on the vehicle body upper side of the rear bumper 14 and at both ends in the vehicle width direction. In the rear combination lamp 20, a tail lamp (brake lamp) 22, a rear turn signal lamp 24, and a backup lamp 26 are juxtaposed in the vertical direction of the vehicle body (see FIG. 2).

  Further, as shown in FIG. 2, the tail lamp 22, the rear turn signal lamp 24, and the backup lamp 26 are provided in their lamp housings 32, 34, and 36 with a light source (for example, a bulb or LED (light emitting diode)) 30; A concave mirror-like reflector (not shown), which is a reflecting plate that reflects diffused light from the light source 30 and reflects light emitted from a headlamp of a rear vehicle, is accommodated.

  A plurality of support protrusions 38 are provided on the rear surfaces of the lamp housings 32, 34, 36 that are open so as to be able to irradiate light from the light source 30, and each of the support protrusions 38 corresponds to the rear end panel 16 of the vehicle body 12. Are supported by a plurality of support members 18 fixed to each other. As a result, the lamp housings 32, 34, 36 are fixed to the vehicle body 12.

  A socket (back cover) 28 for mounting the light source 30 is attached to a substantially central position of each lamp housing 32, 34, 36. The socket 28 has an electrode projecting toward the front of the vehicle body, which is the back side of each lamp housing 32, 34, 36, and electrical wiring (not shown) is connected to the electrode so that the light source 30 can be energized. It is said that.

  Further, the upper end portion of the opening portion 34A of the lamp housing 34 located in the middle and the lower end portion of the opening portion 32A of the lamp housing 32 located on the upper side are integrally connected, and the opening portion 34A of the lamp housing 34 located in the middle portion. The lower end portion of the lamp housing 36 and the upper end portion of the opening 36A of the lamp housing 36 located on the lower side are integrally connected to each other, and light shielding walls 42 and 44 for partitioning the lamp chambers 40 are formed by the respective connecting portions. It is like that.

  A single multicolor lens 50 made of resin is provided to close the openings 32A, 34A, 36A of the lamp housings 32, 34, 36 and form the lamp chamber 40 for each of the lamp housings 32, 34, 36. It has been. The multicolor lens 50 emits light emitted from the light source 30 and reflected by a reflector (not shown) and is color-coded into lamp function colors for each lamp chamber 40.

  That is, as shown in FIG. 4, the multicolor lens 50 is a translucent (or transparent) film-like lens molding sheet in which the lamp functional color (red R in this embodiment) is printed at a predetermined position on the back surface. A member (hereinafter, simply referred to as “sheet member”) 52 is formed by vacuum forming. For example, as shown in FIG. 3, the upper tail lamp 22 is made red R, and the center rear turn signal lamp 24 is The lower backup lamp 26 is a translucent color (clear color) S.

  The rear turn signal lamp 24 emits light in yellow (amber). For this reason, a yellow bulb, LED, or the like is set in the central light source 30, and the rear turn signal lamp 24 functions as a lamp even when the lens color of the multicolor lens 50 in the rear turn signal lamp 24 is a translucent color S. Light is emitted in yellow, which is the color.

  The upper side of the red R portion of the multicolor lens 50 has a curved surface shape (see FIG. 2). Here, when the film-like sheet member 52 is vacuum-formed, the sheet member 52 expands. In particular, the extension of the portion forming the curved surface shape is remarkable. Therefore, as shown in FIG. 5A, the red color R, which is the lamp function color printed on the sheet member 52, is provided with a dark color portion Rd whose color is darker than other portions.

  That is, the dark color portion Rd is provided so that the vicinity of the substantially central portion of the red R portion that is remarkably stretched (having a large curvature) due to the formation of a curved surface is the darkest color, and the dark color portion Rd The density is gradually changed so as to become lighter as it goes to the peripheral portion of the sheet member 52 (multicolor lens 50) so that the degree of expansion of the sheet member 52 is smaller. Or change to light color step by step).

  Therefore, when the sheet member 52 is vacuum-formed and a curved surface is formed in the vicinity of the substantially central portion of the red R portion, the dark color portion Rd is remarkably expanded as the sheet member 52 expands to become a light color. Therefore, as shown in FIG. 5B, the red color R, which is a lamp function color, exhibits a substantially uniform color as a whole.

  Further, in the multicolor lens 50, between different lamp function colors (between the red R portion and the semi-transparent color S portion) is a boundary portion (parting portion) 54 facing the light shielding wall 42. And the front-end | tip part (vehicle body rear side edge part) of each light-shielding walls 42 and 44 is arrange | positioned by the back surface of the multicolor lens 50 in a non-contact state (refer FIG. 2).

  The plate thickness D (see FIG. 5) of the multicolor lens 50 is, for example, D = 0.3 mm to 1.0 mm. Here, the lower limit of the plate thickness D is set to 0.3 mm, and it is difficult to manufacture the multicolor lens 50 having the plate thickness D of less than 0.3 mm, and the upper limit of the plate thickness D is set to 1.0 mm. This is because if the plate thickness D is larger than 1.0 mm, it is difficult to form the multicolor lens 50 by vacuum forming the film-like sheet member 52. That is, by setting the plate thickness D to 0.3 mm to 1.0 mm, the multicolor lens 50 can be easily molded by vacuum molding.

  Next, the operation of the rear combination lamp (vehicle lamp) 20 configured as described above will be described. The multicolor lens 50 according to the present embodiment heats the translucent film-like sheet member 52 having a predetermined portion printed with a lamp functional color (red R in the present embodiment), for example, a substantially hemispherical bulge portion. By sucking the vacuum forming die 60 having 62 and vacuum forming, it is formed into a shape having a curved surface at least partially (red R portion).

  Here, when the film-like sheet member 52 is vacuum-formed, the sheet member 52 expands. In particular, the sheet member 52 extends most remarkably in the vicinity of the substantially central portion (having a large curvature) of the bulging portion 62.

  Therefore, as shown in FIG. 6B, when the sheet member 52 on which the red color R, which is the lamp function color, is printed almost uniformly as in the comparative example shown in FIG. The red R of the portion opposed to the vicinity of the substantially central portion of the portion 62 becomes a light colored portion Ri that becomes lighter as it goes to the vicinity of the substantially central portion, and is a lamp functional color in the multicolor lens 50 after vacuum forming. Red R exhibits a non-uniform color.

  Therefore, in this embodiment, the lamp function color printed on the film-like sheet member 52 before vacuum forming, that is, red R, becomes darker as it goes near the substantially central portion of the bulging portion 62 of the vacuum forming die 60. It is comprised so that it may become.

  In other words, the dark color portion Rd that is the darkest color is provided in the red R region of the film-like sheet member 52 and in the vicinity of the substantially central portion that expands most when the curved surface shape is formed (large curvature). At the same time, the density of the dark color portion Rd is gradually changed so as to become lighter as it goes to the peripheral edge of the sheet member 52 (multicolor lens 50) (as the degree of expansion of the sheet member 52 is smaller). (See FIG. 5A).

  Thereby, in the multicolor lens 50 after vacuum forming, the red color R, which is a lamp function color, exhibits a substantially uniform color as a whole. That is, when the film-like sheet member 52 on which the red color R (lamp function color) with the dark color portion Rd is printed is vacuum-formed with the vacuum forming die 60, the sheet member 52 expands. Since the dark color portion Rd opposed to the substantially central portion of the bulging portion 62 is remarkably expanded, the dark color portion Rd changes to light color (lightened).

  Therefore, as shown in FIG. 5 (B), in the multicolor lens 50 after vacuum forming, the shade of red R, which is the lamp function color, is substantially uniform, so that the overall red color R is exhibited. Become. Thus, when the multicolor lens 50 having a curved surface is formed, a predetermined position of the lamp functional color (red R) printed on the film-like sheet member 52 (a position facing the bulging portion 62 forming the curved surface). In addition, a dark color portion Rd having a darker color than that of other portions may be provided, whereby a film-like multicolor lens 50 exhibiting a substantially uniform lamp functional color (red R) can be obtained. .

  As described above, the method for manufacturing the vehicle lamp according to the present embodiment, the lens of the vehicle lamp, and the lens forming sheet member of the vehicle lamp are applied to the rear combination lamp 20, but the vehicle lamp according to the present embodiment is described. The lamp manufacturing method, the vehicular lamp lens, and the lens forming sheet member of the vehicular lamp are not limited to the illustrated embodiment, and can be appropriately changed in design without departing from the gist of the present invention. Is. For example, the present invention can be applied to other vehicular lamps provided with a fog lamp or the like disposed in the vehicle 10.

  In this embodiment, the lens colors of the multi-color lens 50 in the rear turn signal lamp 24 and the backup lamp 26 are both translucent colors S, and the difference in lamp function color is dealt with by changing the color of the light source 30. That is, the light source 30 of the rear turn signal lamp 24 is composed of a yellow bulb, LED, and the like, and the light source 30 of the backup lamp 26 is composed of a white bulb, LED, and the like.

  However, the difference in the lamp function color between the rear turn signal lamp 24 and the backup lamp 26 may be configured to correspond to the difference in the lens color of the multicolor lens 50. That is, the lens color of the rear turn signal lamp 24 may be yellow, and the lens color of the backup lamp 26 may be a translucent color S.

Schematic perspective view showing the rear side of the vehicle body Schematic side sectional view showing a vehicular lamp (rear combination lamp) Schematic front view showing a multicolor lens Schematic side cross-sectional view showing a vacuum forming mold for vacuum forming a multicolor lens (A) Schematic front view and schematic side view showing sheet member before vacuum forming, (B) Schematic front view and schematic side view showing multicolor lens after vacuum forming (A) Schematic front view and schematic side view showing a sheet member before vacuum forming according to a comparative example, (B) Schematic front view and schematic side view showing a multicolor lens after vacuum forming according to a comparative example

Explanation of symbols

10 Vehicle 20 Rear combination lamp (vehicle lamp)
22 Tail lamp 24 Rear turn signal lamp 26 Backup lamp 30 Light source 32 Lamp housing 34 Lamp housing 36 Lamp housing 40 Lamp chamber 42 Light blocking wall 44 Light blocking wall 50 Multicolor lens (lens)
52 Sheet member (lens molding sheet member)
60 Die for vacuum forming 62 Expanded part R Red (Lamp functional color)
Rd Dark color area Ri Light color area

Claims (9)

A method for producing a lens for a vehicle lamp by vacuum forming a film-like sheet member on which a lamp functional color is printed with a vacuum forming die,
The lamp functional color is provided with a dark portion having a darker color than other portions, and the sheet member is stretched by vacuum forming, so that the dark portion is stretched and lightened, and the lamp functional color is substantially uniform. A method for manufacturing a vehicular lamp characterized by exhibiting a unique color.   2. The method for manufacturing a vehicular lamp according to claim 1, wherein the dark color portion is vacuum-molded with the bulging portion formed on the vacuum-molding die being opposed.   The method for manufacturing a vehicular lamp according to claim 2, wherein the dark portion is darker as it goes near a substantially central portion of the bulge portion.   4. The vehicle according to claim 1, wherein the light and shade of the dark color portion is gradually changed so as to become lighter as the degree of expansion of the seat member is smaller. 5. A method for manufacturing a lamp.   A lens for a vehicle lamp manufactured by the method for manufacturing a vehicle lamp according to any one of claims 1 to 4.   A lens molding sheet member for a vehicular lamp characterized by being formed into a film on which a lamp functional color having a darker color portion darker than other portions is printed.   The lens molding sheet member for a vehicular lamp according to claim 6, wherein a portion to be disposed opposite to a bulging portion formed in a vacuum molding die is the dark color portion.   8. The lens forming sheet member for a vehicular lamp according to claim 7, wherein the sheet member has a darker color as it goes near a substantially central portion of the bulging portion.   The lens molding of the vehicular lamp according to any one of claims 6 to 8, wherein the shading of the dark color portion is gradually changed so as to become lighter as the degree of expansion is smaller. Sheet member.