Manufacturing method for resin molded products

Abstract

To provide a resin molding which has appearance having enhanced three-dimensional feeling compared to a conventional resin molding and is applied with patterns by contrast of different hues.SOLUTION: A resin molding (10) is constituted as a laminate (36) of a transparent resin layer (26) constituting a transparent resin substrate (24) molded into a predetermined shape, a first film (32) which is formed along the transparent resin layer and is composed of a first coloring material, and a second film (34) which is formed along the transparent resin layer and is composed of a second coloring material, wherein the first film (32) is arranged on the most surface side, and includes three regions of a transparent region (TA), a region (CA1) of the first film, and a region (CA2) of the second film when visually recognized from the surface side.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a resin molding used as a vehicle part. Quality Regarding the manufacturing method. [Background technology]

[0002] Conventionally, vehicle parts using resin molded products that have patterns created by laser decoration, in which a reflective metal film is formed on one side of a laminate made of a plate-shaped transparent resin substrate, a colored layer is laminated on the other side, and then a laser is irradiated onto the reflective metal film to peel off part of the reflective metal film, are known (Patent Document 1).

[0003] In the resin molded product disclosed in Patent Document 1, the areas where the metal vapor deposition film is formed are observed as a metallic reflective surface, while the areas where no metal vapor deposition film is formed are observed as the color of the colored layer. In this way, the resin molded product of Patent Document 1 provides an attractive appearance due to the contrast between the two color layers: the reflective metal film on the front side and the colored layer on the back side. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 2019-107789 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in recent years, there has been an increasing need among users for vehicle parts made of resin molded products that have a more three-dimensional appearance.

[0006] The present invention has been made in consideration of the above circumstances, and aims to provide a resin molded product having a pattern with contrasting different color tones, which has an appearance with a more three-dimensional feel than conventional products. [Means for solving the problem]

[0007] In order to achieve the above object, a resin molded product according to one embodiment of the present invention is configured as a laminate of a transparent resin layer constituting a transparent resin substrate molded into a predetermined shape, a first film made of a first coloring material formed along the transparent resin layer, and a second film made of a second coloring material formed along the transparent resin layer, wherein the first film is positioned on the outermost surface side and, when viewed from the outer surface side, has three regions: a transparent region, a region of the first film, and a region of the second film.

[0008] In the above aspect, it is also preferable that the second film region is disposed between the first film region and the transparent region when viewed from the front surface side.

[0009] In the above aspect, it is also preferable that the transparent resin layer is between the first film and the second film.

[0010] In the above aspect, it is also preferable that the second film is located closer to the surface than the transparent resin layer.

[0011] A vehicle component according to another aspect of the present invention is a vehicle component including the resin molded product of the above aspect.

[0012] In addition, another aspect of the present invention provides a method for manufacturing a resin molded product, which comprises a transparent resin layer constituting a transparent resin substrate molded into a predetermined shape, a first film made of a first coloring material formed along the transparent resin layer, and a second film made of a second coloring material formed along the transparent resin layer, and the first film is arranged on the surface side of the second film, and the laminate is then irradiated with a laser from the surface side, focusing on the first film, to peel off a portion of the first film, and the laminate is then irradiated with a laser from the surface side, focusing on the second film, to peel off a portion of the second film, so that three regions, namely the transparent region, the region of the first film, and the region of the second film, are visible from the surface side.

[0013] In the above aspect, it is also preferable that the laminate has the transparent resin layer between the first film and the second film.

[0014] In the above aspect, it is also preferable that the second film is located closer to the surface than the transparent resin layer in the laminate. [Effects of the Invention]

[0015] According to the resin molded product, vehicle part, and method for manufacturing a resin molded product of the above aspects, it is possible to provide products that have an appearance with a more three-dimensional feel than conventional products and have patterns with contrasting color tones. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is a front view of a vehicle lamp including an inner lens that is a resin molded product according to a first embodiment. [Figure 2] 2A is a cross-sectional view taken along line IIA-IIA in FIG. 1, and FIG. 2B is a cross-sectional view taken along line IIB-IIB in FIG. [Figure 3] 1A is a diagram illustrating a cross-sectional structure of an inner lens of a side turn signal lens according to the embodiment, and FIG. 1B is a diagram illustrating the appearance of the inner lens. [Figure 4] 4(A) to 4(E) are diagrams illustrating a method for manufacturing the inner lens. [Figure 5] FIG. 10(A) is a diagram for explaining a cross-sectional structure of an inner lens that is a resin molded product according to a second embodiment, and FIG. 10(B) is a diagram showing the appearance of the inner lens. [Figure 6] 4(A) to 4(E) are diagrams illustrating a method for manufacturing the inner lens. [Figure 7] 10(A) and (C) are diagrams showing a cross-sectional structure of an inner lens of a side turn signal lamp according to a third embodiment of the present invention, and (B) and (D) are diagrams showing the appearance of the inner lens. [Figure 8]FIG. 10 is a front view of a vehicle lamp including an extension that is a resin molded product according to a third embodiment. [Figure 9] FIG. 2 is a horizontal cross-sectional view of the vehicle lamp. [Figure 10] FIG. 2 is a diagram schematically illustrating a cross-sectional structure of the extension. [Figure 11] FIG. 10 is a perspective view schematically showing the appearance of a rear window member that is a resin molded product according to a fourth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0017] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of a resin molded product and a vehicle lamp according to the present invention will be described with reference to the drawings. In the following description of the embodiments, the same components are designated by the same reference numerals, and duplicated descriptions will be omitted.

[0018] (First embodiment) In the first embodiment, a resin molded product according to the present invention is embodied as an inner lens 10 of a vehicle lamp 1, which is a vehicle part. Fig. 1 is a front view of the vehicle lamp 1, and Fig. 2 is a cross-sectional view of the same. As will be described later, the inner lens 10 is provided with a decorative pattern that is visible from the outside, but this is omitted in Figs. 1 and 2.

[0019] The vehicle lamp 1 is a side turn signal lamp that is mounted on the left door mirror 2 when viewed from the front of the vehicle.

[0020] As shown in FIGS. 1 and 2, the vehicle lamp 1 includes a lamp body 12, an outer cover 14, a lamp unit 16, and an inner lens 10.

[0021] The lamp body 12 is assembled inside the door mirror 2, has a curved, elongated shape, and is open toward the front. The outer cover 14 is made of transparent resin and covers the opening at the front of the lamp body 12, and the lamp body 12 and the outer cover 14 define a lamp chamber 20.

[0022] Further, the outer cover 14 is configured so that the visible portion 15 is exposed from the opening 4 provided in the door mirror 2.

[0023] The lamp unit 16 includes a light source substrate 19, a socket 25, and a light guide lens 27. The light source substrate 19 and the socket 25 are provided at the end of the lamp body 12 on the vehicle body side, and the light source substrate 19 has an LED light source 48 provided thereon.

[0024] The light guide lens 27 is a light guide made of a transparent resin material such as polycarbonate resin or acrylic resin, and is elongated and molded to fit the lamp body 12 and the outer cover 14. A plurality of reflective steps 50 are formed at predetermined intervals along the entire length of the light guide lens 27 on the surface facing the outer cover 14. The reflective steps 50 may have various known shapes, such as stippled patterns. When the LED light source 48 is turned on, as shown in FIG. 2(A), a portion of the emitted light enters the light guide lens 27 from the incident portion 54, undergoes repeated internal reflections between the front inner surface 56 and the rear inner surface 58 of the light guide lens 27, and is emitted from the rear end of the vehicle as illumination light L1. The remaining portion of the light is reflected by the reflective steps 50 formed on the rear inner surface 58 of the light guide lens 27 and enters the inner lens 10 as reflected light L2. The light guide lens 27 functions as a surface-emitting light source that emits light uniformly across its entire front surface.

[0025] The inner lens 10 is a resin molded product obtained by molding a transparent resin, such as polycarbonate resin or acrylic resin such as polymethyl methacrylate resin, into a predetermined shape as the transparent resin substrate 24. The inner lens 10 has a shape that fits the rear surface of the outer cover 14, and is disposed between the outer cover 14 and a light guide lens 27. The inner lens 10 is visible from the outside through a visible portion 15 of the outer cover 14. A decorative pattern 30 is applied to the area of ​​the inner lens 10 that is visible from the outside, as will be described later.

[0026] Fig. 3(A) is a diagram showing a schematic cross-sectional structure of the inner lens 10, and Fig. 3(B) is a diagram showing the inner lens 10 as viewed from the front side. In the diagram, the dimensions of each component, particularly the thickness ratios of the transparent resin substrate 24 and the coating film, are exaggerated and shown schematically for ease of understanding, and do not reflect the actual ratios (the same applies to Figs. 4, 5(A), 6, 7(A), and 7(B)).

[0027] As shown in Figure 3(A), the inner lens 10 is generally configured as a laminate 36 of a transparent resin layer 26 that constitutes a transparent resin substrate 24, a first film 32 formed along the front side of the transparent resin layer 26, i.e., the surface facing the outer cover 14, and a second film 34 formed along the back side of the transparent resin layer 26.

[0028] As described above, the transparent resin layer 26 is made of a transparent resin such as polycarbonate resin or acrylic resin. The transparent resin transmits visible light and infrared rays, particularly near-infrared rays with wavelengths of 800 to 1400 nm. The thickness of the transparent resin layer 26 is 2 to several millimeters.

[0029] The first film 32 is a film made of a first coloring material, specifically a metal vapor deposition film. Examples of metals that can be used to form the metal vapor deposition film include aluminum, tin, and stainless steel. In this case, the thickness of the first film 32 is preferably 80 to 200 nm. If the film is too thin, a portion of the incident light will be transmitted, and if the film is too thick, the peeling by laser irradiation, which will be described later, will be incomplete. Alternatively, the first film 32 may be a reflective metal coating containing a metal pigment that can be applied with an air spray or the like to achieve a mirror finish. In this case, the thickness of the first film 32 is preferably 15 to 20 nm. Thus, the first film 32 is a reflective metal film with a metallic appearance.

[0030] The second film 34 is a film made of a second coloring material, and is a colored coating film. For example, an acrylic or urethane resin paint containing a black pigment (e.g., a black azo pigment) can be used as the raw material for the colored coating film. This paint containing a black pigment absorbs infrared rays, particularly near-infrared rays with wavelengths of 800 to 1400 nm. The thickness of the second film 34 is preferably 15 to 20 nm.

[0031] The laminate 36 includes a first film-free region NA1 where the first film 32 is not formed, and a second film-free region NA2 where the second film is not formed. The first film-free region NA1 and the second film-free region NA2 form a decorative pattern 30 as shown in Fig. 3(B). While a decorative pattern 30a of designed character strings and a decorative pattern 30b of two curved lines are shown as examples, the decorative pattern 30 is not limited to these and can have any shape, such as dots, marks, or more complex patterns.

[0032] When viewed from the outer cover 14 side, i.e., the front side, the inner lens 10 has a first film area CA1 where the metallic reflective surface of the first film 32 is recognized, a second film area CA2 where the color of the second film 34 is recognized, and a transparent area TA where the transparent resin substrate 24 is recognized.

[0033] Here, the first film region CA1 is the region of the first film 32 excluding the first film-free region NA1. The second film region CA2 is the region of the second film 34 that is visible through the first film-free region NA1. The transparent region TA is the region of the first film-free region NA1 that corresponds to the second film-free region NA2. The decorative pattern 30 is designed to be formed by combining the second film region CA2 and the transparent region TA. This allows the decorative pattern 30 to be designed using three different combinations: the first film region CA1, which has an overall metallic luster; the transparent region TA, which gives a transparent impression; and the color of the second film region CA2 (black in this example), thereby increasing the variety of contrast.

[0034] For this reason, the area CA2 of the second film and the transparent area TA may be provided in a state where they are not adjacent to each other, as in decorative pattern 30b. Also, if the area CA2 of the second film is arranged between the area CA1 of the first film and the transparent area TA, as in decorative pattern 30a, the area CA2 of the second film acts as a border for the transparent area TA between the glossy reflective surface in the front and the transparent area TA in the back, creating an appearance with a more three-dimensional sense of depth.

[0035] In particular, in this embodiment, the area CA2 of the second film is located behind the transparent area TA, which can further enhance the impression of depth.

[0036] The above description applies to the appearance of the vehicle lamp 1 in the daytime when it is not lit. When it is lit at night, illumination light is irradiated through the transparent area TA, giving the viewer a fresh impression that is different from that seen in the daytime.

[0037] The second film 34 is not limited to black and may be any color as long as it uses a pigment that absorbs infrared rays (near-infrared rays with wavelengths of 800 to 1400 nm). For example, pigments such as azo red (red), phthalocyanine blue (blue), and azo yellow (yellow) can be used. Examples of suitable paints include acrylic resins such as acrylic urethane, acrylic silicone, and acrylic lacquer, epoxy resins, and resin-based paints such as polyphenyl resin, polystyrene resin, and polypropylene resin. These paints only need to have a spectral transmittance of 50% or more for the infrared laser light used for laser irradiation. Black second film 34 is particularly preferable because it provides a clear color contrast between the first film region CA1 and the transparent region TA.

[0038] Next, we will explain the manufacturing method of the inner lens 10. In the manufacturing method of the inner lens 10, first, a transparent resin substrate 24 is prepared by injection molding a transparent resin such as polycarbonate into a predetermined shape of the inner lens.

[0039] Next, aluminum is vapor-deposited on the front surface of the transparent resin substrate 24 by a technique such as resistance heating vapor deposition, to form the first film 32.

[0040] Next, the second film 34 is formed on the back surface of the transparent resin substrate 24 by a method such as air spraying.

[0041] The laminate 36 thus formed is then laser decorated. Figure 4 is a diagram illustrating a method for laser decorating the laminate 36.

[0042] First, as shown in Fig. 4(A), the focal length of the laser marker 90 is set to a distance d1 so that the focus of the laser marker 90 coincides with the first film 32. As shown in Fig. 4(B), a laser beam LB1 is irradiated to peel off (cut off) the first film 32 in an area corresponding to a pre-designed first film-non-formation area NA1.

[0043] Next, the workpiece (laminate 36) is held as is, and the focal length of the laser marker 90 is set to a distance d2 so that the focal point of the laser marker 90 coincides with the second film 34, as shown in FIG. 4(C). Then, as shown in FIG. 4(D), a laser LB2 is irradiated to peel off (cut) the second film 34 in an area corresponding to the pre-designed second film-free area NA2. As a result, as shown in FIG. 4(E), an inner lens 10 can be manufactured in which, when viewed from the front side, three areas are visible: the transparent area TA, the first film area CA1, and the second film area CA2.

[0044] The laser marker 90 can be an infrared laser marker such as a YVO4 laser, a YAG laser, or a CO2 laser. It is preferable to use a YVO4 laser or a YAG laser. This is because both the YVO4 laser and the YAG laser have a wavelength of 1064 nm and are highly absorbed by metals, resulting in a beautiful finish. The type of laser to be used can be selected depending on the material of the laminate 36. For example, a YVO4 laser has high transmittance to polycarbonate and is advantageous when the transparent resin substrate 24 is made of polycarbonate.

[0045] The laser irradiation method is not particularly limited, and a laser plotter (flatbed laser), a galvano laser, or the like can be appropriately selected.

[0046] According to the above method, the black color of the second film area CA2 is placed between the first film area CA1, which has an overall metallic color, and the transparent area TA, which gives an impression of transparency, thereby making it possible to produce a resin molded product with an attractive appearance and a sense of depth.

[0047] Furthermore, according to the manufacturing method of this embodiment, the laser irradiation to the first film 32 and the laser irradiation to the second film 34 can be performed without turning the workpiece over, while the workpiece is held in the same state, thereby preventing misalignment that occurs when the workpiece is turned over. As a result, misalignment of the decoration position can be prevented.

[0048] (Second embodiment) Fig. 5(A) is a diagram schematically showing the cross-sectional structure of the inner lens 110 of a vehicle lamp 100 according to the second embodiment, and Fig. 5(B) is a diagram showing the inner lens 110 as viewed from the front side. The vehicle lamp 100 has the same configuration as the vehicle lamp 1 according to the first embodiment except for the cross-sectional structure of the inner lens 110, i.e., the arrangement of the transparent resin layer 26, the first film 32, and the second film 34, and therefore a duplicated description will be omitted.

[0049] As shown in Figure 5(A), the inner lens 110 is roughly configured as a laminate 36 of a transparent resin layer 26 that constitutes the transparent resin substrate 24, a first film 32 formed along the surface side of the transparent resin layer 26, i.e., the side facing the outer cover 14, and a second film 34 formed along the transparent resin layer 26 between the first film 32 and the transparent resin layer 26.

[0050] That is, inner lens 10 and inner lens 110 have in common the fact that, in their cross-sectional structures, first film 32 is positioned closest to the surface, but differ in that, in inner lens 10, transparent resin layer 26 is located between first film 32 and second film 34, whereas in inner lens 110, second film 34 is located closer to the surface than transparent resin layer 26.

[0051] When viewed from the outer cover 14 side, i.e., the front side, the inner lens 110 has a first film area CA1 where the metallic reflective surface of the first film 32 is recognized, a second film area CA3 where the color of the second film 34 is recognized, and a transparent area TA where the transparent resin layer 26 is recognized.

[0052] 5(B), the decorative pattern 130 is designed to be formed by a combination of the area CA2 of the second film and the transparent area TA. This allows the decorative pattern 130 to be designed using three different combinations: the area CA1 of the first film having an overall metallic color, the transparent area TA giving an impression of transparency, and the area CA3 of the second film having the color of the second film 34 (black in this example), thereby achieving the same effect as the first embodiment.

[0053] Due to the difference in arrangement, in the second film region CA2 of the inner lens 10, the second film 34 is visible on the back side of the transparent resin layer 26, whereas in the second film region CA3 of the inner lens 110, the second film 34 is visible on the front side of the transparent resin layer 26, i.e., on the forefront. For this reason, even if the second film region CA3 of the inner lens 110 and the second film region CA2 of the inner lens 10 are the same color (black in this example), they give slightly different impressions. Therefore, in this embodiment, it is possible to further increase the variation in contrast.

[0054] Next, a method for manufacturing the inner lens 110 will be described. First, the inner lens 110 is formed into the desired shape of the inner lens 10 by injection molding a transparent resin such as polycarbonate. Next, a second film 34 is formed on the surface side of the transparent resin substrate 24 using the same method as in the first embodiment, and a first film is formed on the second film 34 to form a laminate 136.

[0055] Next, as shown in Fig. 6, laser decoration is performed on the laminate 136. First, as shown in Fig. 6(A), the focal length of the laser marker 90 is set to a distance d3 so that the focus of the laser marker 90 coincides with the first film 32. As shown in Fig. 6(B), a laser LB3 is irradiated to peel off (cut off) the first film 32 in an area corresponding to a pre-designed first film-non-forming area NA1.

[0056] Next, while holding the workpiece (laminate 136) as is, the focal length of the laser marker 90 is set to a distance d4 so that the focal point of the laser marker 90 coincides with the second film 34, as shown in FIG. 6(C). Then, as shown in FIG. 6(D), a laser beam LB4 is irradiated to peel off (cut) the second film 34 in an area corresponding to the pre-designed second film-free area NA2. As a result, as shown in FIG. 6(E), an inner lens 10 can be manufactured in which, when viewed from the front side, three areas are visible: the transparent area TA, the first film area CA1, and the second film area CA3.

[0057] In this way, even with the inner lens 110 according to this embodiment, by adjusting the focal length so that the focal point of the laser marker 90 coincides with the first film 32 when peeling off the first film 32, and so that the focal point of the laser marker 90 coincides with the second film 34 when peeling off the second film 34, it is possible to manufacture an inner lens 110 that has the same effect as the inner lens 10. This eliminates the need to turn the workpiece over, and also prevents misalignment of the decoration position.

[0058] In this embodiment, the first film 32 and the second film 34 are adjacent to each other, resulting in a short focal distance. This minimizes the risk of adversely affecting the above-described effects. However, even if such a risk exists, it can be addressed by adjusting the laser irradiation energy. For example, if the first film 32 is a metal-evaporated film and the second film 34 is a non-metallic colored coating film, the laser irradiation energy required for peeling the first film 32 is smaller than that for the second film 34, and therefore the impact on the second film 34 is minimal. Thus, it is preferable to select materials for the first film 32 and the second film 34 so that the laser energy required for peeling the second film 34 is greater than that for the first film 32. For example, if the first film 32 is an aluminum-evaporated film, the required output energy is 20%, whereas if the second film 34 is a black paint film, the required output energy is 60%.

[0059] (Third embodiment) 7(A) and 7(C) are diagrams schematically showing the cross-sectional structure of the inner lens 210 of a vehicular lamp 200 according to the third embodiment, and FIGS. 7(B) and (D) are diagrams of the inner lens 210 viewed from the front side. FIGS. 7(A) and (B) show the vehicular lamp 200 in a non-illuminated state, and FIGS. 7(B) and (D) show the vehicular lamp 200 in a lit state. The vehicular lamp 200 has the same configuration as the vehicular lamp 1 according to the first embodiment, except for the materials of the first film 232 and the second film 234 formed on the laminate 236 that constitutes the inner lens 110, and therefore, a duplicated description will be omitted.

[0060] In the inner lens 210, the first film 232 is a half-mirror vapor-deposited film made of the same metal material as the first film 32. The thickness of the first film 232 is preferably 20 to 80 nm. If the thickness of the first film 232, which is a metal reflective film, is less than 20 nm, the function of reflecting incident light is weakened, and if it is greater than 80 nm, the function of transmitting incident light is weakened, and the film is unable to function as a half-mirror that transmits part of the incident light and reflects part of it.

[0061] The second film 234 is a colored transparent coating film that absorbs infrared light and partially transmits visible light. Materials for the second film 234 include acrylic resin-based paints, such as acrylic urethane, acrylic silicone, and acrylic lacquer, epoxy resin-based paints, and resin-based paints, such as polyphenyl resin, polystyrene resin, and polypropylene resin, that use pigments that absorb infrared light and partially transmit visible light. The colored transparent paint is preferably a black transparent paint that absorbs infrared light, but is not limited to this. Any colored paint that absorbs infrared light and partially transmits visible light can be used. In this specification, "black transparent" refers to a black color that is visible light transmissive, such as gray smoke.

[0062] 7(A), when the vehicle lamp 200 is turned off during the daytime, the inner lens 210 reflects natural light on the surface of the first film 232, and the area CA4 of the first film presents the appearance of a metallic reflective surface similar to that of the inner lens 10. On the other hand, the area CA5 of the second film presents the color of the colored transparent paint.

[0063] As a result, the decorative pattern 230 has an appearance formed by a combination of the second film area CA5 and the transparent area TA within the first film area CA4, which has the appearance of a metallic reflective surface. This allows the decorative pattern 230 to be designed using three different combinations: the first film area CA4, which has an overall metallic luster; the transparent area TA, which gives an impression of transparency; and the color of the second film area CA5 (preferably black), thereby achieving the same effect as the first embodiment.

[0064] On the other hand, when the vehicular lamp 200 is turned on at night, in the transparent region TA, the light emitted from the light guide lens 27 is transmitted through the transparent region TA and irradiated toward the front of the vehicle (the surface side of the inner lens 210). As a result, the transparent region TA has a bright appearance. In the region CA4 of the first film, the light emitted from the light guide lens 27 passes through the second film 234, and is irradiated toward the front of the vehicle as light with the color tone of the second film 234, passing through the first film. As a result, the region CA4 of the first film has an appearance of emitting dark light with the color tone of the second film 234. In the region CA5 of the second film, the light emitted from the light guide lens 27 passes through the second film 234, and is irradiated toward the front of the vehicle as light with the color tone of the second film 234, passing through the transparent resin layer 26. As a result, the area CA5 of the second film appears to emit light in the color tone of the second film.

[0065] As a result, when the lamp is turned on, as shown in Figure 7(D), decorative pattern 230 can be designed using three different combinations: area CA4 of the first film that emits a dim light with the color tone of the second film, a bright and shining transparent area TA, and area CA5 of the second film that emits light with the color tone of the second film, thereby providing a more varied appearance.

[0066] (Fourth embodiment) 8 and 9 are diagrams showing a vehicle lamp 300 equipped with an extension 310, which is a vehicle part that embodies a resin molded product according to a fourth embodiment of the present invention. The vehicle lamp 300 is a right-side headlamp that is disposed on the right side when viewed from the front of the vehicle.

[0067] The vehicle lamp 300 includes a container-shaped lamp body 312 that opens at the front, an outer cover 314 that covers the front opening of the lamp body 312 and defines a lamp chamber 320, a lamp unit 316, a clearance lamp light source 318, and an extension 310. The lamp unit 316 mainly includes a projection lens 317, an LED light source 322, a reflector, and a shade. The lamp unit 316 is configured to be switchable between high beam and low beam.

[0068] The clearance lamp light source 18 is, for example, a halogen bulb, and is disposed to the side of the lighting unit 316 .

[0069] The extension 310 is a resin molded product obtained by molding a transparent resin, such as polycarbonate resin or acrylic resin such as polymethyl methacrylate resin, into a predetermined shape as the transparent resin base material 324. The extension 310 is disposed between the lamp unit 316 and the outer cover 314, and its front shape corresponds to the front shape of the vehicle lamp 300.

[0070] A circular opening 340 is provided on one side of the center of the extension 310. A lighting unit 316 is disposed behind the opening 340, and a projection lens 317 of the lighting unit 316 protrudes from the opening 340. When the LED light source 322 is turned on, the irradiated light passes through the opening 340 and is emitted forward.

[0071] A clearance lamp light transmitting region 328 is provided on the opposite side of the opening 340 with respect to the center of the extension 310, and a clearance lamp light source 318 is disposed behind the region 328.

[0072] A number of steps 350 are formed on the back surface of the clearance lamp light transmitting area 328 in the extension 310, and when the clearance lamp light source 318 is turned on, the light emitted from the clearance lamp light source 318 passes through the clearance lamp light transmitting area 328 via the steps 350 and is emitted forward as diffused light.

[0073] As shown in FIG. 10 , the cross-sectional structure of the extension 310 is generally similar to that of the inner lens 110 of the second embodiment. Specifically, a colored coating film similar to the second film 34 is formed on the surface of a transparent resin substrate 324 injection-molded to the shape of the extension 310, as a second film 334. A reflective metal film similar to the first film 32 is formed on the second film 334 as a first film 332. In a front view, decorative patterns 330a and 330b are formed in the second film region CA7 around the periphery of the clearance lamp light-transmitting region 328 of the extension 310, where the first film region CA6 is visible as a whole, and around the opening 340. In addition, a transparent region TA and a character string formed in the second film region are formed as a decorative pattern 330c in the upper left corner. The clearance lamp light-transmitting region 328 is a transparent region TA1 with a step on its back surface.

[0074] In this way, an appearance with a sense of depth can be achieved in the same way as in the above embodiment with the extension 310. Furthermore, although the extension 310 has a step or the like on the back side, since the laser is irradiated from one direction on the front side, there is no difficulty in making the clearance lamp light transmitting area the transparent area TA.

[0075] (Fifth embodiment) 11 shows a rear window member 400 as a vehicle part according to the fifth embodiment. The rear window member 400 is formed as a single rectangular panel extending laterally to replace the rear window glass and its peripheral panel of an existing vehicle.

[0076] 11, the rear window member 400 includes a transparent resin base material 424. The transparent resin base material 324 has a panel shape corresponding to the rectangular panel shape of the rear window member 400, with one surface in the thickness direction serving as the front surface and the other surface serving as the vehicle inner surface.

[0077] The transparent resin substrate 424 is molded using a transparent resin such as polycarbonate resin. A band-shaped peripheral panel region 460 of a predetermined width, which corresponds to the peripheral panel, is provided at the lower edge of the rear window member 400. The peripheral panel region 460 has roughly the same cross-sectional structure as the inner lens 10 of the first embodiment and includes a first film and a second film (not shown) formed on the front surface of the transparent resin substrate 424. The peripheral panel region 460 is visually recognized as the first film region CA7, and the first film region CA7, the second film region CA8, and the transparent region TA form a decorative pattern 430. In this way, the present invention can also be applied to a rear window member that is a part that partially replaces a vehicle body panel.

[0078] Although the embodiments of the present invention have been described above, the present invention is not limited to these and can be applied to various vehicle parts. Furthermore, it goes without saying that various modifications and alterations based on the present disclosure are included within the scope of the present invention. [Explanation of symbols]

[0079] 24: Transparent resin base material 26: Transparent resin layer 32: First membrane 34: Second membrane 36: Laminate 136: Laminate 232: First membrane 234: Second membrane 236: Laminate 324: Transparent resin base material 332: First membrane 334: Second membrane 424: Transparent resin base material

Claims

[Claim 1] a laminate including a transparent resin layer constituting a transparent resin substrate formed into a predetermined shape, a first film formed along the transparent resin layer and made of a first coloring material, and a second film formed along the transparent resin layer and made of a second coloring material, the first film being disposed on a surface side relative to the second film; and a laser beam focused on the first film is irradiated from the surface side to peel off a portion of the first film; irradiating the laminate with a laser beam from the front surface side while focusing on the second film to peel off a portion of the second film; three regions, namely, a transparent region, a region of the first film, and a region of the second film, are visible from the front surface side; A method for manufacturing a resin molded product, wherein the laminate has the transparent resin layer between the first film and the second film.

Images