JPH02116526A - Constituting method of reflection layer of lamp housing - Google Patents

Abstract

PURPOSE:To obtain favorable reflection properties with a simple process, by a method wherein at the time when a lamp housing is injection-molded of synthetic resin, injection molding is performed by inserting a flexible metallic film constituting a reflection layer. CONSTITUTION:An aluminum metallized layer 9d and an adhesive layer 9e which is on one side of the layer 9d are stratified in an in-mold foil 9. The in-mold foil 9 is held by facing the adhesive layer 9e and a base film 9a respectively on a mold (female) 10 and a mold (male) 8. A lamp housing I is injection- molded of synthetic resin under a state where the in-mold foil 9 is placed between the molds 8, 10 by pressing both the molds 8, 10 against each other. When mold break is performed by moving the mold (male) 8 backward in the direction of an arrow (c), the molded lamp housing 1 is taken out. A part of the in-mold foil 9 pressed between the molds 8, 10 is stuck to the inside of the lamp housing 1 by leaving behind the base film 9a and a mold release layer 9b and a reflection layer 12 is formed.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method for forming a reflective layer on the inner surface of a lamp housing made of synthetic resin such as ABS, PP, or AAS to reflect light emitted from a light source bulb. It is something.

[Conventional technology]

Conventional techniques commonly used to construct a reflective layer on the inner surface of a synthetic resin lamp housing can be roughly divided into:
Reflective coating treatment method, vapor deposition treatment method, and FIG. 4 is an explanatory diagram of the reflective coating treatment method.

A reflective paint is applied by a spray gun 2 to the inner surface of a lamp housing 1 injection-molded with synthetic resin.

FIG. 7 is a cross-sectional view of a part of the lamp housing having a reflective layer formed by the above-mentioned reflective coating treatment method.

A reflective coating film 3 is formed on the inner surface of a housing base 1' made of a synthetic resin material.

However, the reflective layer composed of a coating film like this,
The reflection characteristics are not very good, and the light distribution characteristics are limited. Moreover, there is a problem in that it is difficult to obtain a sense of brightness in the lamp body.

FIG. 8 is a cross-sectional view of a reflective layer constructed by the above-mentioned vapor deposition method. To construct such a reflective layer, an undercoat 4 is applied to the inner surface of the housing base 1' made of a synthetic resin material by air spraying (not shown), and a metal such as aluminum is vapor-deposited thereon. A vapor deposited layer 5 is formed by using a vapor deposition layer 5, and a top coat 6 is further formed thereon by air spraying (not shown).

To carry out this vapor deposition method, a vapor deposition processing apparatus is required, resulting in an enormous equipment cost.

Moreover, since it involves an undercoat painting process and a topcoat painting process, it requires a great deal of time and labor, and the manufacturing cost is high.

In addition, if the reflector is constructed and installed separately from the synthetic resin lamp housing, the number of components is large, installation is labor-intensive, and it is also heavy and costly. There are some problems.

The present invention has been made in view of the above-mentioned circumstances, and it provides good reflection characteristics, can be manufactured in a simple process, does not require expensive equipment, and has the potential to increase the weight of the lamp housing. It is an object of the present invention to provide a method for configuring a lamp housing reflective layer without the above.

[Means for Solving the Problems] The basic principle of the method of the present invention, which was created to achieve the above object, is that when a lamp housing is injection molded from a synthetic resin material, a flexible metal film constituting the second reflective layer is used. is inserted and injection molded.

The metal film is formed of a metal vapor deposited film in order to improve reflection characteristics and obtain flexibility.

In order for the metal vapor deposited film to adhere to the inner surface of the lamp housing, an adhesive layer is layered on the metal vapor deposited film in advance to form an in-mold foil, and this in-molded film is sandwiched between injection molds. Perform injection molding.

As a specific configuration for adapting the above-mentioned principle to industrial production, the method for configuring a reflective layer of the present invention includes the following steps: a method for configuring a reflective layer on the inner surface of a synthetic resin lamp housing. the foil-like material is sandwiched between a pair of molds for synthetic resin injection molding, and the adhesive layer of the foil-like material is opposed to the concave mold; The lamp housing is injection molded from a synthetic resin material with a foil-like material sandwiched between a pair of molds, and a metal vapor deposition film is fixed to the inner surface of the lamp housing via the adhesive layer. do.

[Effect]

According to the above structure, the reflective layer is formed at the same time as injection molding, so the process is simple.

Moreover, since the foil-like material is mass-produced in a specialized factory, it can be supplied at a low cost with stable quality.

Furthermore, since vapor deposition equipment is not required in the lamp housing manufacturing factory, the equipment cost is low.

Furthermore, since a metal vapor deposited film is used as the reflective layer, it has excellent reflective properties, can be constructed lightweight, and does not require an increase in the number of component parts.

〔Example〕

FIG. 1 is a schematic diagram showing an example of a method for constructing a reflective layer according to the present invention.

A mold (female) 10 is fixed to the base.

The mold (male) 8 is pressed toward the mold (female) 10 as shown by the arrow a, and the injector 7 approaches and comes into contact with it as shown by the arrow A, thereby injecting the molten synthetic resin material under pressure.

An in-mold foil 9 is held and sandwiched between the mold (female) 10 and the mold (male) 8.

An enlarged cross section of the in-mold foil 9 is shown in FIG.

The main component of this in-mold foil 9 is the aluminum vapor deposited layer 9.
d, and an adhesive layer 9e laminated on one surface thereof.

A protective layer 9C is formed on the other surface of the aluminum vapor deposited layer 9d, and this protective layer 9C is adhered to the base film 9a via a release layer 9b.

The in-mold foil 9 of this example is formed into a long strip and rolled, and as shown in FIG.

FIG. 3 is an enlarged sectional view of the vicinity of a part of FIG. 1. The in-mold foil 9 has the adhesive layer 9e facing the mold (female) 10,
The base film 9a is held facing the mold (male) 8.

As shown in FIG. 4, the lamp housing 1 is injection molded from a synthetic resin material with both molds 8 and 10 pressed against each other and the in-mold foil 9 sandwiched therebetween.

As shown in FIG. 5, when the mold (male) 8 is moved back in the direction of arrow C and opened, the molded lamp housing 1 is taken out.

The portion of the in-mold foil 9 pressed between the molds 8 and 10 adheres to the inner surface of the lamp housing 1, leaving the base film 9a and the release layer 9b, to form a reflective film 12.

The members constituting this reflective film 12 will be explained with reference to FIG. 2: an aluminum vapor deposition layer 9d attached to the inner surface of the housing 1 via an adhesive layer 9e, and a protective layer 9 covering this.
c.

This embodiment has the configuration described above.

Since a reflective layer having an aluminum vapor deposited layer 9d is formed on the inner surface of the lamp housing 1, it exhibits good reflective characteristics.

Since the reflective layer 12 is formed at the same time as the injection molding of the lamp housing 1, the process is simple, and the equipment cost is low because the lamp housing manufacturing department does not require vapor deposition equipment.

Since the reflective layer is formed of a metal (aluminum) vapor deposited film, the increase in weight of the lamp housing 1 is negligible.

〔Effect of the invention〕

As explained above, according to the method for configuring the lamp housing reflective layer according to the present invention, good reflective properties can be obtained by the metal vapor deposited film, and the reflective layer can be formed in a simple process that is performed simultaneously with the injection molding of the lamp housing. constructed and lightweight,
It has an excellent practical effect of being inexpensive.

[Brief explanation of drawings]

FIG. 1 is a schematic explanatory diagram showing an embodiment of a method for constructing a lamp housing reflective layer according to the present invention, and FIG. 2 is an enlarged sectional view of a mold foil in the above embodiment. 3 to 5 are process diagrams in the above embodiment. FIGS. 6 to 8 are explanatory diagrams of methods for forming a reflective layer in the prior art, respectively. DESCRIPTION OF SYMBOLS 1... Lamp housing, 1'... Synthetic resin base of lamp housing, 2... Spray gun, 3... Reflective coating film, 4... Undercoat, 5... Vapor deposition layer, 6...
・Top coat, 7... Injector, 8... Mold (male), 9... In-mold foil, 9a... Base film, 9b... Release layer, 9c... Protective layer, 9d
...Aluminum vapor deposited layer as an example of a metal vapor deposited layer, 9e.
... Adhesive layer, 10... Mold (female), 12... Reflective film.

Claims (1)

[Claims] 1. A method for forming a reflective layer on the inner surface of a synthetic resin lamp housing, comprising: forming a foil member having a metal vapor deposited film and an adhesive layer; The above-mentioned foil-like material is sandwiched between the molds, and the adhesive layer of the foil-like material is made to face the concave mold, and with the foil-like material sandwiched between the pair of molds, a synthetic resin material is used. A method for constructing a reflective layer of a lamp housing, comprising injection molding a lamp housing, and adhering a metal vapor deposition film to the inner surface of the lamp housing via the adhesive layer.