Vehicle lamp fitting and manufacturing method of the same

Abstract

To provide a vehicle lamp fitting which enables easy assembly while securing a wide light emission surface of an inner lens relative to an outer lens in a lateral direction.SOLUTION: A vehicle lamp fitting includes: a radiation part 20; an inner lens 40 located rearward of the radiation part; and an outer lens 50 located rearward of the inner lens. The outer lens has guide protrusions and a positioning protrusion protruding forward. The inner lens has guide holes and a positioning hole. Each guide protrusion is inserted into the guide hole while forming gaps in a lateral direction. The positioning protrusion is inserted into the positioning hole to position the inner lens relative to the outer lens in the lateral direction.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a vehicle lamp and a method for manufacturing the vehicle lamp. [Background technology]

[0002] There is known a vehicle lighting fixture in which rear combination lamps mounted on both corners of the rear end of the vehicle and a lid lamp mounted on the back gate of the vehicle are arranged side by side in the vehicle width direction (for example, Patent Document 1 listed below). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2018-106941 Summary of the Invention [Problem to be solved by the invention]

[0004] In such vehicle lamps, a gap between the lid lamp and the rear combination lamp creates a dark area between the light-emitting area on the lid lamp side and the light-emitting area on the rear combination lamp side. Therefore, by positioning the left and right ends of the inner lens of the lid lamp close to the inner surface of the outer lens, the light-emitting area on the lid lamp side and the light-emitting area on the rear combination lamp side become a continuous light-emitting area, improving the appearance of the light emission. However, when the side wall portions of the outer lens are recessed in the left and right directions, it is difficult to position the inner lens in the storage space of the outer lens, making it difficult to reduce the distance between the side wall portions of the outer lens and the ends of the inner lens.

[0005] The present invention was proposed in consideration of the above-mentioned conventional circumstances, and aims to provide a vehicle lamp that can be easily assembled while ensuring that the light-emitting surface of the inner lens is wide in the left-right direction relative to the outer lens. [Means for solving the problem]

[0006] In order to achieve the above object, the present invention provides the following means. [1] A vehicle lamp that is located at the rear end of a vehicle and irradiates light to the rear of the vehicle, an illumination unit that illuminates the rear side with light; an inner lens located behind the irradiation unit and extending in the left-right direction; an outer lens located behind the inner lens and extending in the left-right direction; The outer lens is a guide protrusion and a positioning protrusion arranged in the left-right direction and protruding forward; sidewall portions extending forward from the left and right ends of the outer lens; and inner protrusions protruding inward in the left-right direction from front ends of the side wall portions, The inner lens is a fixing portion fixed to the outer lens; a guide hole and a positioning hole that penetrate in the front-rear direction of the vehicle, The left and right ends of the inner lens face the side wall portions with a gap therebetween and overlap the inner protrusions as viewed from the front-rear direction, The guide protrusions are inserted into the guide holes with a gap in the left-right direction, The positioning protrusion is inserted into the positioning hole, thereby positioning the inner lens relative to the outer lens in the left-right direction. [2] The guide protrusion is located on a first side in the left-right direction with respect to the positioning protrusion, the outer lens has a stopper protrusion located on the first side of the guide protrusion, the inner lens has a protruding piece that protrudes in the vertical direction relative to the inner lens and in which the guide hole is provided, The vehicle lamp according to [1], wherein a recess recessed toward the front side is formed between the guide protrusion and the stopper protrusion. [3] The guide protrusion is located on a first side in the left-right direction with respect to the positioning protrusion, The guide protrusion is A tip portion and a first inclined surface located on the first side with respect to the tip portion; a second inclined surface located on a second side opposite to the first side with respect to the tip portion, the first inclined surface is inclined in a direction toward the front side as it approaches the first side, the second inclined surface is inclined in a direction toward the front side as it approaches the second side, The vehicle lamp according to [1], wherein an inclination angle of the first inclined surface with respect to the left-right direction is larger than an inclination angle of the second inclined surface with respect to the left-right direction. [4] The outer lens has a plurality of the guide protrusions arranged on both sides of the positioning protrusion in the left-right direction, The vehicle lamp according to [1], wherein the inner lens has a plurality of the guide holes arranged on both sides of the positioning hole in the left-right direction. [5] The positioning protrusion is located at the center of the outer lens in the left-right direction, The vehicle lamp according to [4], wherein the positioning hole is located at the center of the inner lens in the left-right direction. [6] A housing that opens to the rear and accommodates the irradiation unit, The vehicle lamp according to [1], wherein the inner protrusion is welded to the housing at a front end portion. [7] A lid lamp mounted on a trunk lid of the vehicle, the lid lamp having the illumination unit, the inner lens, and the outer lens; The vehicle lamp according to any one of [1] to [6], further comprising: a pair of rear combination lamps arranged side by side on the right and left sides of the lid lamp, respectively. [8] A method for manufacturing a vehicle lamp that is located at the rear end of a vehicle and irradiates light to the rear of the vehicle, comprising: a lens assembling step of fixing an inner lens extending in the left-right direction to an outer lens located behind the inner lens and extending in the left-right direction; The outer lens is a guide protrusion and a positioning protrusion arranged in the left-right direction and protruding forward; sidewall portions extending forward from the left and right ends of the outer lens; and inner protrusions protruding inward in the left-right direction from front ends of the side wall portions, The inner lens is a guide hole and a positioning hole that penetrate in the front-rear direction of the vehicle, the guide protrusion is located on a first side in the left-right direction with respect to the positioning protrusion, The lens assembly process includes: a first step of positioning a first end portion of the inner lens on the first side forward of a second end portion of the inner lens on a second side opposite to the first side, the first end portion facing an inner surface of the side wall portion, and inserting the guide protrusion portion into the guide hole; a second step of moving the second end portion rearward while maintaining the guide protrusion portion inserted into the guide hole, and inserting the positioning protrusion portion into the positioning hole; and a third step of fixing the inner lens to the outer lens, In the first step, the guide protrusion is inserted into the guide hole with a gap in the left-right direction, In the second step, the inner lens is positioned relative to the outer lens in the left-right direction by inserting the positioning protrusion into the positioning hole. [Effects of the Invention]

[0007] As described above, according to the present invention, it is possible to provide a vehicle lamp that can be easily assembled while ensuring that the light-emitting surface of the inner lens is wide in the left-right direction relative to the outer lens. [Brief explanation of the drawings]

[0008] [Figure 1]FIG. 1 is a rear view of a vehicle on which a vehicle lamp according to an embodiment is mounted. [Figure 2] FIG. 2 is a view of the lid lamp and the rear combination lamp of the embodiment as seen from the rear side. [Figure 3] 3 is a cross-sectional view of the vehicle lamp taken along line III-III in FIG. [Figure 4] FIG. 4 is a front view of a semi-assembled product of an inner lens and an outer lens according to one embodiment. [Figure 5] FIG. 5 is an enlarged view of region V shown in FIG. [Figure 6] FIG. 6 is an enlarged view of region VI shown in FIG. [Figure 7] FIG. 7 is an enlarged view of region VII shown in FIG. [Figure 8] 8 is a cross-sectional view of the first guide protrusion, the stopper protrusion, and the first projecting piece taken along the line VIII-VIII in FIG. [Figure 9] 9 is a cross-sectional view of the positioning convex portion and the fourth projecting piece taken along line IX-IX in FIG. [Figure 10] FIG. 10 is a schematic cross-sectional view illustrating a first step of a lens assembly process according to an embodiment. [Figure 11] FIG. 11 is a partially enlarged view of FIG. [Figure 12] FIG. 12 is a schematic cross-sectional view illustrating a second step of the lens assembly process according to one embodiment. [Figure 13] FIG. 13 is a partially enlarged view of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the drawings used in the following description, the dimensions of the components may be shown at different scales to make them easier to see, and the dimensional ratios of the components may not necessarily be the same as in reality.

[0010] In addition, in the drawings shown below, an XYZ Cartesian coordinate system is set. The Y-axis direction is the longitudinal direction of the vehicle 100 on which the vehicle lamp 1 is mounted, with the +Y side being the front side and the -Y side being the rear side. The X-axis direction is the lateral direction (vehicle width direction) of the vehicle 100 on which the vehicle lamp 1 is mounted, with the +X side being the right side and the -X side being the left side. The Z-axis direction is the vertical direction of the vehicle lamp 1, with the +Z side being the upper side and the -Z side being the lower side.

[0011] Fig. 1 is a front view of a rear portion 60 of a vehicle 100 equipped with a vehicle lamp 1 of this embodiment, viewed from the rear side (-Y). As shown in Fig. 1, the vehicle lamp 1 includes a lid lamp LID mounted on a trunk lid 100a of the vehicle 100, and rear combination lamps RCL mounted on both corners of the rear end of the vehicle 100. The lid lamp LID and the rear combination lamp RCL are arranged side by side in the left-right direction X of the vehicle 100. The vehicle lamp 1 is located at the rear end of the vehicle 100 and irradiates light to the rear side (-Y) of the vehicle 100.

[0012] The vehicle lamp 1 is configured to be symmetrical with respect to a center line L that is located at the center of the left-right direction X when viewed from the front-rear direction Y and extends in the up-down direction Z. In this specification, "inside in the left-right direction X" means the side closer to the center line L in the left-right direction X, and "outside in the left-right direction X" means the side away from the center line L in the left-right direction X.

[0013] 2 is a front view of the lid lamp LID and the rear combination lamp RCL located to the right of the lid lamp LID, as seen from the rear (-Z) side. In FIG. 2, the light-emitting area A1 of the lid lamp LID and the light-emitting area A2 of the rear combination lamp RCL are illustrated as dot patterns.

[0014] Light emitting region A1 has a uniform width and extends linearly along the left-right direction X. Light emitting region A2 extends from the boundary with light emitting region A1 outward in the left-right direction X with the same width as light emitting region A1. Light emitting region A2 has a larger width at its outer end in the left-right direction X.

[0015] In the vehicle lamp 1, when the trunk lid 100a is closed, these light emitting areas A1 and A2 emit light so as to extend in the left-right direction X.

[0016] Fig. 3 is a cross-sectional view of the vehicle lamp 1 taken along line III-III in Fig. 2. Note that Fig. 3 illustrates the right (+X) end of the lid lamp LID and the right (+Y) rear combination lamp RCL, but the left (-X) end of the lid lamp LID and the left (-X) rear combination lamp RCL also have the same structure when inverted in the left-right direction X.

[0017] The lid lamp LID has a housing 10, an irradiation unit 20, an inner lens 40, and an outer lens 50. The housing 10, the irradiation unit 20, the inner lens 40, and the outer lens 50 are arranged in this order from the front side (+Y) to the rear side (-Y).

[0018] The housing 10 is fixed to the vehicle 100. The housing 10 has a bottom wall portion 11 extending along a plane perpendicular to the front-rear direction Y, and a frame-shaped portion 12 protruding rearward (−Y) from the bottom wall portion 11. This leaves the housing 10 open on the rear side.

[0019] The illumination unit 20 is housed in an opening on the rear side (-Y) of the housing 10 and illuminates light toward the rear side (-Y). The illumination unit 20 has a rod-shaped light guide 25 extending in the left-right direction X, and a pair of light source devices 21 disposed at the right and left ends of the light guide 25. Note that only one of the pair of light source devices 21, the right side (+X), is shown in FIG. 3.

[0020] The light guide 25 is made of a translucent material such as glass or a transparent resin such as polycarbonate or acrylic. The light guide 25 guides the light emitted from the light source device 21. The light guide 25 curves in an arch shape toward the front (+Y) side as it moves from the center to the right and left sides in the left-right direction X. An incident portion 25a is provided at each end of the light guide 25 in the left-right direction X. The incident portion 25a faces the light source device 21.

[0021] The light source device 21 has a substrate 21a and an LED light source 21b mounted on the substrate 21a. The LED light source 21b emits light toward the incident surface of the incident portion 25a. The light emitted from the LED light source 21b is guided from the incident portion 25a into the inside of the light guide 25 and guided in the left-right direction X. Furthermore, this light is emitted approximately uniformly from the entire length of the light guide 25 to the rear side (-Y) due to the action of a reflection cutter (not shown) provided on the surface of the light guide 25 facing the front side (+Y). As a result, the light guide 25 emits light approximately uniformly along its entire length.

[0022] The inner lens 40 is located on the rear side (-Y) of the irradiation unit 20. The inner lens 40 is a plate-shaped member made of a translucent material such as a transparent resin such as polycarbonate or acrylic, or glass, and is a lens that transmits light emitted from the light guide 25.

[0023] 4 is a view of the inner lens 40 and the outer lens 50 as seen from the front side (+Z). In the assembly process of the lid lamp LID, the inner lens 40 and the outer lens 50 are fixed together in advance to form a semi-assembled product SA shown in FIG.

[0024] The inner lens 40 has an inner lens main body 49 and a plurality of protruding pieces 41, 42, 43, 44 protruding upward from the upper edge of the inner lens main body 49. The inner lens main body 49 extends in the left-right direction X. That is, the inner lens 40 extends in the left-right direction X. It is a diffusion lens that diffuses light emitted from the light guide 25. In this embodiment, the ends 40a, 40b of the inner lens 40 are the ends of the inner lens main body 49 in the left-right direction X.

[0025] The protruding pieces 41, 42, 43, and 44 are each plate-shaped and extend along a plane perpendicular to the front-rear direction Y. The multiple protruding pieces 41, 42, 43, and 44 are arranged side by side in the left-right direction. In the following description, they are referred to as a first protruding piece 41, a second protruding piece (fixing portion) 42, a third protruding piece (fixing portion) 43, and a fourth protruding piece (fixing portion) 44. The inner lens 40 has two first protruding pieces 41, two second protruding pieces 42, two third protruding pieces 43, and one fourth protruding piece 44. The fourth protruding piece 44 is arranged on a center line L of the vehicular lamp 1 in the left-right direction X. The two first protruding pieces 41 are arranged symmetrically with respect to the center line L. The two second protruding pieces 42 are arranged symmetrically with respect to the center line L. The two third protruding pieces 43 are arranged symmetrically with respect to the center line L. Therefore, one first protruding piece 41, one second protruding piece 42, and one third protruding piece 43 are arranged on the right (+X) and left (-X) sides of the center line L. The first protruding piece 41 is arranged outward in the left-right direction X from the second protruding piece 42 and the third protruding piece 43. The third protruding piece 43 is arranged inward in the left-right direction X from the first protruding piece 41 and the second protruding piece 42. The second protruding piece 42 is arranged between the first protruding piece 41 and the third protruding piece 43 in the left-right direction X.

[0026] FIG. 5 is an enlarged view of region V shown in FIG. 5, the first protruding piece 41 has a rectangular shape when viewed in the front-rear direction Y. A first guide hole 41h is provided in the first protruding piece 41. The first guide hole 41h penetrates the first protruding piece 41 in the front-rear direction. The first guide hole 41h is an elongated hole having a uniform width and extending in the left-right direction.

[0027] The second protruding piece 42 has a trapezoidal shape when viewed in the front-rear direction Y. A first fixing hole 42k is provided in the second protruding piece 42. The first fixing hole 42k penetrates the second protruding piece 42 in the front-rear direction. The first fixing hole 42k is an elongated hole with a uniform width that extends in the left-right direction.

[0028] FIG. 6 is an enlarged view of region VI shown in FIG. As shown in FIG. 6, the third protruding piece 43 has a trapezoidal shape when viewed in the front-rear direction Y. The third protruding piece 43 is provided with a second guide hole 43h and a second fixing hole 43k. The second guide hole 43h and the second fixing hole 43k are arranged side by side in the left-right direction X. The second fixing hole 43k is located more inward in the left-right direction X than the second guide hole 43h (on the right side (+X) of the third protruding piece 43 shown in FIG. 6). The second guide hole 43h and the second fixing hole 43k penetrate the third protruding piece 43 in the front-rear direction. The second guide hole 43h is an elongated hole having a uniform width and extending in the left-right direction. The second fixing hole 43k is also an elongated hole having a uniform width and extending in the left-right direction.

[0029] FIG. 7 is an enlarged view of region VII shown in FIG. As shown in FIG. 7, the fourth protruding piece 44 has a trapezoidal shape when viewed in the front-rear direction Y. The fourth protruding piece 44 is provided with a positioning hole 44h and a third fixing hole 44k. The positioning hole 44h and the third fixing hole 44k are arranged side by side in the left-right direction X. The third fixing hole 44k is located to the right (+X) of the positioning hole 44h. The positioning hole 44h and the third fixing hole 44k penetrate the fourth protruding piece 44 in the front-rear direction. The positioning hole 44h is an elongated hole having a uniform width and extending in the left-right direction. The positioning hole 44h is arranged on the center line L of the vehicle lamp 1 in the left-right direction X. The third fixing hole 44k is circular.

[0030] The first guide hole 41h, the second guide hole 43h, and the positioning hole 44h have the same width, and the first guide hole 41h and the second guide hole 43h have the same length in the left-right direction X and are greater than the length in the left-right direction X of the positioning hole 44h.

[0031] Fixing screws 9 for fixing the inner lens 40 to the outer lens 50 are inserted into the first fixing hole 42k, the second fixing hole 43k, and the third fixing hole 44k. Therefore, the second protruding piece 42, the third protruding piece 43, and the fourth protruding piece 44 function as fixing portions that are fixed to the outer lens 50. The inner lens 40 has a plurality of fixing portions (the second protruding piece 42, the third protruding piece 43, and the fourth protruding piece 44) aligned in the left-right direction X.

[0032] As shown in FIG. 3 , the outer lens 50 is located on the rear side (-Y) of the inner lens 40. The outer lens 50 is a plate-shaped cover lens that covers the opening of the housing 10. The outer lens 50 protects each component of the lid lamp LID from the rear side (-Y). The outer lens 50 of this embodiment is molded by two-color molding using a transparent resin, such as polycarbonate or acrylic, and a resin material that does not transmit light. The outer lens 50 transmits light emitted from the inner lens 40 to the rear side (-Y) and emits it to the rear of the vehicle 100. The inner lens 40 includes a transmissive region 50A corresponding to the light-emitting region A1 and a non-transmissive region 50B other than the transmissive region 50A. The transmissive region 50A is molded from a transparent resin that transmits light, and the non-transmissive region 50B is molded from a resin that does not transmit light, such as a black resin. The transmissive region 50A overlaps the light-emitting region A1 when viewed from the rear side (-Y). On the other hand, the non-transparent area 50B overlaps the protruding pieces 41, 42, 43, 44, guide protrusions 51, 52, stopper protrusion 53, positioning protrusion 54, and multiple fixing screws 9 shown in FIG. 4 when viewed from the rear side (-Y), making them less visible.

[0033] As shown in Fig. 3, the outer lens 50 has an outer lens main body 59, a pair of side walls 58, a pair of inner protrusions 57, and a fixing surface 50f (see Fig. 4). The side walls 58 and the inner protrusions 57 are provided on the right and left sides of the outer lens 50, respectively. Note that Fig. 3 shows only one of the side walls 58 and the inner protrusion 57 located on the right side.

[0034] As shown in FIG. 4 , the outer lens main body 59 extends in the left-right direction X. That is, the outer lens 50 extends in the left-right direction X. The fixing surface 50f is a surface facing the front side (+Y) of the outer lens main body 59. The fixing surface 50f is provided with four guide protrusions 51, 52 that protrude toward the front side (+Y), two stopper protrusions 53, and one positioning protrusion 54. That is, the outer lens 50 has the four guide protrusions 51, 52, the two stopper protrusions 53, and the one positioning protrusion 54. The four guide protrusions 51, 52, the two stopper protrusions 53, and the one positioning protrusion 54 are aligned in the left-right direction X. In the following description, when distinguishing between two of the four guide protrusions 51, 52 located on the right side of the center line L and two located on the left side, these will be referred to as the first guide protrusion 51 and the second guide protrusion 52. The outer lens 50 of this embodiment has two first guide protrusions 51 and two second guide protrusions 52.

[0035] The positioning protrusion 54 is disposed on the center line L of the vehicular lamp 1 in the left-right direction X. The two first guide protrusions 51 are disposed symmetrically with respect to the center line L. The two second guide protrusions 52 are disposed symmetrically with respect to the center line L. The two stopper protrusions 53 are disposed symmetrically with respect to the center line L. Therefore, one first guide protrusion 51, one second guide protrusion 52, and one stopper protrusion 53 are disposed on the right (+X) and left (-X) sides of the center line L. The stopper protrusion 53 is disposed outward of the first guide protrusion 51 and the second guide protrusion 52 in the left-right direction X. The second guide protrusion 52 is disposed inward of the first guide protrusion 51 and the stopper protrusion 53 in the left-right direction X.

[0036] As shown in FIG. 5 , the first guide protrusions 51 and the stopper protrusions 53 are rib-shaped and extend in the left-right direction X. The dimension of the first guide protrusions 51 in the left-right direction X is smaller than the dimension of the first guide holes 41h in the left-right direction X. The first guide protrusions 51 are inserted into the first guide holes 41h with gaps in the left-right direction X. That is, when the first guide protrusions 51 are inserted into the first guide holes 41h, gaps are provided between the right end of the first guide protrusions 51 and the right end of the inner edge of the first guide holes 41h, and between the left end of the first guide protrusions 51 and the left end of the inner edge of the first guide holes 41h. On the other hand, the dimension of the first guide protrusions 51 in the up-down direction Z is approximately the same as or slightly smaller than the dimension of the first guide holes 41h in the up-down direction Z. Therefore, by inserting the first guide protrusions 51 into the first guide holes 41h, the inner lens 40 is positioned relative to the outer lens 50 in the up-down direction Z.

[0037] 8 is a cross-sectional view of the first guide protrusion 51, the stopper protrusion 53, and the first protruding piece 41 taken along line VIII-VIII in FIG. 5. The first guide protrusion 51 has a tip 51t, a first inclined surface 51a, and a second inclined surface 51b. The tip 51t is the portion of the first guide protrusion 51 that is located at the rearmost side (-Y).

[0038] The first inclined surface 51a is located on the outer side in the left-right direction X with respect to the tip portion 51t (the right side (+X) of the first guide protrusion 51 in FIG. 8). The first inclined surface 51a inclines toward the front side (+Y) as it extends outward in the left-right direction X. The second inclined surface 51b is located on the inner side in the left-right direction X with respect to the tip portion 51t (the left side (-X) of the first guide protrusion 51 in FIG. 8). The second inclined surface 51b inclines toward the front side (+Y) as it extends inward in the left-right direction X. The inclination angle α of the first inclined surface 51a with respect to the left-right direction X is larger than the inclination angle β of the second inclined surface 51b with respect to the left-right direction. Note that the inclination angle with respect to the left-right direction X refers to the angle with respect to the Y-axis extending in the left-right direction X when the vehicular lamp 1 is viewed from the up-down direction Z. In this embodiment, the first inclined surface 51a and the second inclined surface 51b both extend linearly when viewed from the up-down direction Z. The first inclined surface 51a and the second inclined surface 51b may be curved.

[0039] 5, the stopper protrusion 53 is disposed on the outer side in the left-right direction X relative to the first guide protrusion 51 (on the left side (-X) of the stopper protrusion 53 shown in FIG. 5). When the first guide protrusion 51 is inserted into the first guide hole 41h, the stopper protrusion 53 is disposed on the outer side in the left-right direction X relative to the first protruding piece 41.

[0040] As shown in FIG. 8, between the stopper protrusion 53 and the first guide protrusion 51, a recess 56 recessed toward the front side (+Y) is formed.

[0041] As shown in FIG. 6, the second guide protrusion 52 is rib-shaped and extends in the left-right direction X. The dimension of the second guide protrusion 52 in the left-right direction X is smaller than the dimension of the second guide hole 43h in the left-right direction X. The second guide protrusion 52 is inserted into the second guide hole 43h of the third protruding piece 43 with a gap in the left-right direction X. The dimension of the second guide protrusion 52 in the up-down direction Z is approximately the same as or slightly smaller than the dimension of the second guide hole 43h in the up-down direction Z. Therefore, the inner lens 40 is positioned in the up-down direction Z relative to the outer lens 50. Although not shown, the second guide protrusion 52 has a tip portion, a first inclined surface, and a second inclined surface similar to those of the first guide protrusion 51 shown in FIG. 8.

[0042] As shown in FIG. 7 , the positioning protrusion 54 is rib-shaped and extends in the left-right direction X. The positioning hole 44h is disposed on the center line L of the vehicle lamp 1 in the left-right direction X. The dimension of the positioning protrusion 54 in the left-right direction X is approximately the same as or slightly smaller than the dimension of the positioning hole 44h in the left-right direction X. Therefore, by inserting the positioning protrusion 54 into the positioning hole 44h, the inner lens 40 is positioned in the left-right direction X relative to the outer lens 50. Furthermore, the dimension of the positioning protrusion 54 in the up-down direction Z is approximately the same as or slightly smaller than the dimension of the positioning hole 44h in the up-down direction Z. Therefore, the inner lens 40 is positioned in the up-down direction Z relative to the outer lens 50.

[0043] 9 is a cross-sectional view of the positioning protrusion 54 and the fourth projecting piece 44 taken along line IX-IX in FIG. 5. The positioning protrusion 54 has a shape symmetrical with respect to the center line L. A tapered surface may be provided at the tip of the positioning protrusion 54 to guide the insertion of the positioning protrusion 54.

[0044] The fixing surface 50f of the outer lens 50 is provided with a first screw hole 55a that overlaps with the first fixing hole 42k as shown in Fig. 5, a second screw hole 55b that overlaps with the second fixing hole 43k as shown in Fig. 6, and a third screw hole 55c that overlaps with the third fixing hole 44k as shown in Fig. 7. Fixing screws 9 are fastened into the first screw hole 55a, the second screw hole 55b, and the third screw hole 55c, respectively.

[0045] As shown in FIG. 3 , the side wall portions 58 extend forward (+Y) from the ends of the outer lens 50 in the left-right direction X. The inner lens 40 is disposed between the pair of side wall portions 58 in the left-right direction X. Although not shown, the outer lens 50 further has an upper wall portion that covers the inner lens 40 from above and a lower wall portion that covers the inner lens 40 from below. Therefore, the inner lens 40 is disposed between the upper wall portion and the lower wall in the up-down direction Z. As a result, the outer lens 50 surrounds the inner lens 40 on all sides, as well as the rear side (-Y). In other words, the outer lens 50 forms an accommodation space C that accommodates the inner lens 40.

[0046] The inner protrusions 57 protrude inward in the left-right direction X from the front (+Y) ends of the side wall portions 58. The inner protrusions 57 protrude toward each other in the left-right direction X (inward in the left-right direction X). The front ends 57a of the inner protrusions 57 are joined to the rear end 12a of the frame-shaped portion 12 of the housing 10. In this embodiment, the front end 57a of the inner protrusions 57 and the rear end 12a of the frame-shaped portion 12 are joined by hot plate welding. Note that the outer lens 50 is welded to the housing 10 not only at the inner protrusions 57 but also at the upper and lower wall portions (not shown) located above and below the inner lens 40. As a result, the outer lens 50 is welded and fixed to the housing 10 around the entire periphery of the front (+Y) opening. The method for welding the inner protrusions 57 to the frame-shaped portion 12 is not limited to this embodiment and may be, for example, laser welding or ultrasonic welding.

[0047] The side wall portion 58 has an inner surface 58f. The inner surface 58f of the side wall portion 58 located on the right side (+X) faces the left side (-X). The inner surface 58f of the side wall portion 58 (not shown in FIG. 3) located on the left side (-X) faces the right side (+X).

[0048] According to this embodiment, by employing a structure for fixing the inner lens 40 to the outer lens 50, the inner lens 40 can be arranged to overlap the welded portion between the housing 10 and the outer lens 50 (i.e., the rear end 12a and the front end 57a) in the front-rear direction Y, and the inner lens 40 can be made larger in the left-right direction X. This makes it possible to bring the end 40b of the inner lens 40 in the left-right direction X closer to the rear combination lamp RCL, and makes it possible to make the light-emitting area A1 of the lid lamp LID and the light-emitting area A2 of the rear combination lamp RCL appear integrated.

[0049] (Method of assembling vehicle lighting fixtures) Next, a method for assembling the vehicle lamp 1 of this embodiment will be described. The method for assembling the vehicle lamp 1 described below is part of a method for manufacturing the vehicle lamp 1. The method for assembling the vehicle lamp 1 includes a lens assembly process for fixing the inner lens 40 to the outer lens 50 to assemble a semi-assembled product SA. The lens assembly process of this embodiment includes at least a first process, a second process, and a third process.

[0050] As shown in FIG. 3 , the inner lens 40 of this embodiment is accommodated in the accommodation space C and fixed to the outer lens 50. According to this embodiment, the end 40a of the inner lens 40 in the left-right direction X overlaps the inner protrusion 57 in the front-rear direction Y. Therefore, in the lens assembling process of this embodiment, the left (−X) end (hereinafter referred to as the first end 40a) of the inner lens 40 is placed in the accommodation space C, and then the right (+X) end (hereinafter referred to as the second end 40b) is placed in the accommodation space C. The assembly process of this embodiment will be described in more detail below. As described above, the inner lens 40 and the outer lens 50 of this embodiment have bilaterally symmetrical shapes with respect to the center line L of the vehicle lamp 1. Therefore, the lens assembling process of this embodiment may be performed in a reversed order. More specifically, the lens assembling process may be performed in a manner that the second end 40b of the inner lens 40 is placed in the accommodation space C, and then the first end 40a is placed in the accommodation space C.

[0051] Fig. 10 is a schematic cross-sectional view illustrating the first step of the lens assembly process. Fig. 11 is a partially enlarged view of Fig. 10. As shown in Fig. 10, in the first step, only the first end 40a is inserted into the housing space C, and the second end 40b is positioned outside the housing space C (on the front side (+Y) of the housing space C).

[0052] 11, through the first step, the first end 40a faces the inner surface 58f of the side wall portion 58. Also, in the first step, the worker or the assembly device (hereinafter simply referred to as the worker) abuts the first protruding piece 41 on the left side (-X) of the inner lens 40 against the restricting surface 53a of the stopper protrusion 53 on the left side (-X) of the outer lens 50. Furthermore, the worker inserts the first guide protrusion 51 into the first guide hole 41h.

[0053] FIG. 8 shows the first locus T1 of the first protruding piece 41 in the first step. As shown by the first locus T1, in the first step, the worker places the left (-X) end of the first protruding piece 41 in the recess 56, thereby aligning the first guide protrusion 51 with the first guide hole 41h in the front-rear direction Y and facilitating insertion. In the first step, the inner lens 40 is inserted into the accommodation space C by moving the first end 40a toward the side wall 58 of the outer lens 50 (i.e., toward the left (-X)). Therefore, in the first step, the first protruding piece 41 moves in a direction along the first inclined surface 51a of the first guide protrusion 51. In this embodiment, the first inclined surface 51a is inclined at an inclination angle α along the first locus T1 of the first protruding piece 41 in the first step.

[0054] In the first step, the first protruding piece 41 is brought into contact with the restricting surface 53a of the stopper protrusion 53 located on the left side (-X) of the first guide protrusion 51. Therefore, after the first step, the first guide protrusion 51 is positioned biased toward the right region of the first guide hole 41h. That is, after the first step, the gap formed between the right end of the first guide protrusion 51 and the right end of the inner edge of the first guide hole 41h is smaller than the gap formed between the left end of the first guide protrusion 51 and the left end of the inner edge of the first guide hole 41h. This allows the worker to bring the first end 40a of the inner lens 40 close to and face the side wall portion 58 without contacting the side wall portion 58.

[0055] Fig. 12 is a schematic cross-sectional view illustrating the second step of the lens assembly process. Fig. 13 is a partially enlarged view of Fig. 12. As shown in Fig. 12, in the second step, the worker rotates the inner lens 40 to move the second end 40b to the rear side (-Y), and the second end 40b is accommodated in the accommodation space C. As shown in Fig. 13, the second step is performed while maintaining the first guide protrusion 51 inserted in the first guide hole 41h.

[0056] In the second step of this embodiment, the second end 40b is moved to the rear (-Y) side with the first end 40a of the inner lens 40 positioned close to the side wall 58 of the outer lens 50. Therefore, in the second step, the inner lens 40 is positioned biased toward the left (-X) side of the storage space C until the positioning protrusion 54 is inserted into the positioning hole 44h, and the first end 40a is located to the left (-X) side of the left (-X) inner protrusion 57. According to the second step of this embodiment, by moving the second end 40b to the rear (-Y) side with the first end 40a positioned to the left of the left (-X) inner protrusion 57 inside the storage space C, the second end 40b can be positioned in the storage space C without interfering with the right inner protrusion 57.

[0057] FIG. 9 shows the second locus T2 of the fourth protruding piece 44 of the inner lens 40 in the second step. As shown by the second locus T2, in the second step, the second end 40b of the inner lens 40 moves from the front to the rear (-Y) side, thereby inserting the positioning protrusion 54 into the positioning hole 44h. Before the second step (i.e., after the first step), the positioning protrusion 54 and the positioning hole 44h face each other in the front-rear direction Y but are slightly misaligned in the left-right direction X. In this embodiment, the positioning protrusion 54 has a tapered surface 54c at its tip. Therefore, even if the center of the positioning protrusion 54 is misaligned with the center of the positioning hole 44h, the positioning protrusion 54 is guided into the positioning hole 44h. By inserting the positioning protrusion 54 into the positioning hole 44h, the inner lens 40 is positioned relative to the outer lens 50 in the left-right direction X.

[0058] 8 shows the third locus T3 of the first protruding piece 41 in the second step. By inserting the positioning protrusion 54 into the positioning hole 44h and positioning the inner lens 40 with respect to the outer lens 50, the inner lens 40 moves to the right (+X).

[0059] The second inclined surface 51b of the first guide protrusion 51 is formed at an inclination angle β along the third locus T3 of the first protruding piece 41 in the second step. In the second step, the first guide protrusion 51 is inserted into the first guide hole 41h while the inner edge of the first guide hole 41h is guided by the second inclined surface 51b.

[0060] In the third step of the lens assembly process, an operator fixes the inner lens 40 to the outer lens 50. More specifically, as shown in FIG. 4, the operator uses fixing screws 9 to fix the protruding pieces 41, 42, 43, and 44 of the inner lens 40 to the surface of the outer lens 50 facing the front (+Y) side. Through the above steps, a semi-assembled product SA in which the inner lens 40 and the outer lens 50 are integrated is manufactured.

[0061] (Summary of the embodiment) According to the above-described configuration, the ends 40a, 40b of the inner lens 40 in the left-right direction X can be arranged to overlap the inner protrusion 57 in the front-rear direction Y on the rear side (-Y) of the inner protrusion 57 of the outer lens 50. Therefore, the ends 40a, 40b of the inner lens 40 can be arranged outward in the left-right direction X from the inner protrusion 57. As a result, the dimension of the inner lens 40 in the left-right direction X can be increased, and when lamps such as rear combination lamps RCL are arranged on both sides of the inner lens 40 in the left-right direction X, it becomes easier to make the light-emitting region A1 appear continuous with the light-emitting region A2.

[0062] Furthermore, with the above-described configuration, the ends 40a, 40b of the inner lens 40 of the lid lamp LID in the left-right direction X can be brought closer to the rear combination lamp RCL, thereby realizing a vehicle lamp 1 in which the light-emitting areas A1, A2 of the lid lamp LID and the rear combination lamp RCL appear integrated.

[0063] While the embodiments and modifications of the present invention have been described above, the configurations and combinations thereof in the embodiments and modifications are merely examples, and additions, omissions, substitutions, and other modifications of the configurations are possible without departing from the spirit of the present invention. Furthermore, the present invention is not limited to the embodiments.

[0064] For example, in the above-described embodiment, a case has been described in which a plurality of guide holes are provided in the inner lens and a plurality of guide protrusions are provided in the outer lens. However, the numbers of guide holes and guide protrusions are not limited to those in the above-described embodiment, and one each of these may be provided in the inner lens and the outer lens. [Explanation of symbols]

[0065] DESCRIPTION OF SYMBOLS 1...vehicle lamp, 10...housing, 20...illumination portion, 40...inner lens, 40a, 40b...end portion, 41...first protruding piece, 42...second protruding piece (fixing portion), 43...third protruding piece (fixing portion), 44...fourth protruding piece (fixing portion), 44h...positioning hole, 49...inner lens main body portion, 50...outer lens, 51...guide convex portion, 51a...first inclined surface, 51b...second inclined surface, 51t...tip portion, 53...stopper convex portion, 54...positioning convex portion, 56...recess, 57...inner protruding portion, 57a...front end portion, 58...side wall portion, 58f...inner surface, 59...outer lens main body portion, 100...vehicle, 100a...trunk lid, LID...lid lamp, RCL...rear combination lamp, X...left-right direction, Y...front-rear direction, Z...up-down direction, α, β...tilt angle

Claims

1. A vehicle lamp that is located at a rear end of a vehicle and irradiates light to the rear of the vehicle, an illumination unit that illuminates the rear side with light; an inner lens located behind the irradiation unit and extending in the left-right direction; an outer lens located behind the inner lens and extending in the left-right direction; The outer lens is a guide protrusion and a positioning protrusion arranged in the left-right direction and protruding forward; sidewall portions extending forward from the left and right ends of the outer lens; and inner protrusions protruding inward in the left-right direction from front ends of the side wall portions, The inner lens is a fixing portion fixed to the outer lens; a guide hole and a positioning hole that penetrate in the front-rear direction of the vehicle, The left and right ends of the inner lens face the side wall portions with a gap therebetween and overlap the inner protrusions as viewed from the front-rear direction, The guide protrusions are inserted into the guide holes with a gap in the left-right direction, The positioning protrusion is inserted into the positioning hole, thereby positioning the inner lens relative to the outer lens in the left-right direction. Vehicle lighting fixtures.

2. the guide protrusion is located on a first side in the left-right direction with respect to the positioning protrusion, the outer lens has a stopper protrusion located on the first side of the guide protrusion, the inner lens has a protruding piece that protrudes in the vertical direction relative to the inner lens and in which the guide hole is provided, A recess recessed toward the front side is formed between the guide protrusion and the stopper protrusion.

2. A vehicle lamp according to claim 1.

3. the guide protrusion is located on a first side in the left-right direction with respect to the positioning protrusion, The guide protrusion is A tip portion and a first inclined surface located on the first side with respect to the tip portion; a second inclined surface located on a second side opposite to the first side with respect to the tip portion, the first inclined surface is inclined in a direction toward the front side as it approaches the first side, the second inclined surface is inclined in a direction toward the front side as it approaches the second side, an inclination angle of the first inclined surface with respect to the left-right direction is larger than an inclination angle of the second inclined surface with respect to the left-right direction; 2. A vehicle lamp according to claim 1.

4. the outer lens has a plurality of the guide protrusions arranged on both sides of the positioning protrusion in the left-right direction, The inner lens has a plurality of guide holes arranged on both sides of the positioning hole in the left-right direction.

2. A vehicle lamp according to claim 1.

5. the positioning protrusion is located at the center of the outer lens in the left-right direction, The positioning hole is located at the center of the inner lens in the left-right direction.

5. A vehicle lamp according to claim 4.

6. a housing that opens to the rear and accommodates the irradiation unit; the inner projection is welded to the housing at a front end; 2. A vehicle lamp according to claim 1.

7. a lid lamp mounted on a trunk lid of the vehicle, the lid lamp having the illumination unit, the inner lens, and the outer lens; a pair of rear combination lamps arranged side by side on the right and left sides of the lid lamp, respectively; The vehicle lamp according to any one of claims 1 to 6.

8. A method for manufacturing a vehicle lamp that is located at a rear end of a vehicle and irradiates light to a rear side of the vehicle, comprising: a lens assembling step of fixing an inner lens extending in the left-right direction to an outer lens located behind the inner lens and extending in the left-right direction; The outer lens is a guide protrusion and a positioning protrusion arranged in the left-right direction and protruding forward; sidewall portions extending forward from the left and right ends of the outer lens; and inner protrusions protruding inward in the left-right direction from front ends of the side wall portions, The inner lens is a guide hole and a positioning hole that penetrate in the front-rear direction of the vehicle, the guide protrusion is located on a first side in the left-right direction with respect to the positioning protrusion, The lens assembly process includes: a first step of positioning a first end portion of the inner lens located on the first side forward of a second end portion of the inner lens located on a second side opposite to the first side, the first end portion facing an inner surface of the side wall portion, and inserting the guide protrusion portion into the guide hole; a second step of moving the second end portion rearward while maintaining the guide protrusion portion inserted into the guide hole, and inserting the positioning protrusion portion into the positioning hole; and a third step of fixing the inner lens to the outer lens, In the first step, the guide protrusion is inserted into the guide hole with a gap in the left-right direction, In the second step, the positioning protrusion is inserted into the positioning hole, thereby positioning the inner lens relative to the outer lens in the left-right direction. A method for manufacturing a vehicle lamp.

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