Resin molded articles

Abstract

To provide a resin-molded article which enables reduction of manufacturing costs.SOLUTION: In a resin-molded article (10), a light guide (20) into which light can enter, a light emitter (40) capable of emitting light using the light entering from the light guide (20), and a base material (50) that supports the light guide (20) and the light emitter (40) are integrally formed. An emitting surface (20a) of the light guide (20) and an incident surface (46) of the light emitter (40) are spaced apart from each other so as to face each other with an air layer (21) interposed therebetween.SELECTED DRAWING: Figure 2

Description

Technical Field

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[0001] The present invention relates to a resin molded product provided with a light guide.

Background Art

[0002] Some resin molded products include a light guide that spreads and emits the light incident from a light source in a linear or planar shape. The prior art regarding resin molded products provided with a light guide is disclosed in Patent Document 1.

[0003] The light guide disclosed in Patent Document 1 is adopted in vehicle lamps. This light guide of the vehicle lamp includes a rod-shaped portion into which the light from the light source is incident, and a plate-shaped portion having an edge arranged along the rod-shaped portion.

Prior Art Document

Patent Document

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] If the rod-shaped portion and the plate-shaped portion are integrally molded from the same material, the boundary between the rod-shaped portion and the plate-shaped portion becomes ambiguous, and the light incident on the base end of the rod-shaped portion hardly reaches the tip of the rod-shaped portion and immediately enters the plate-shaped portion. As a result, it becomes difficult to uniformly illuminate the portion of the plate-shaped portion far from the light source. Therefore, Patent Document 1 discloses molding the rod-shaped portion and the plate-shaped portion using different resin materials, or including a light diffusing material in the material forming the plate-shaped portion. However, there is room for improvement from the perspective of manufacturing cost.

[0006] An object of the present invention is to provide a resin molded product capable of suppressing manufacturing cost.

Means for Solving the Problems

[0007] This disclosure provides a light guide having a light-emitting surface into which light can be incident, A light-emitting body having an incident surface into which light emitted from the light-emitting surface of the light guide can be incident, and which is capable of emitting light when light is incident from the incident surface, A substrate having a light guide side support portion that supports the light guide and a light emitter side support portion that supports the light emitter is integrally formed. A resin molded product is provided in which the emission surface of the light guide and the incident surface of the light-emitting body are separated from each other by an air layer. [Effects of the Invention]

[0008] This invention can provide a resin molded product that can reduce manufacturing costs. [Brief explanation of the drawing]

[0009] [Figure 1] Figure 1A shows a resin molded product according to an embodiment mounted on the instrument panel of a vehicle. Figure 1B is a cross-sectional view taken along the line 1B-1B in Figure 1A. [Figure 2] Figure 1A is a perspective view of the resin molded product. [Figure 3] Figure 2 is an exploded perspective view of the resin molded product. [Figure 4] This is a diagram of a resin molded product viewed from a direction opposite to the surface of the light-emitting element. [Figure 5] This is a diagram of a resin molded product viewed from the back of the light-emitting element. [Figure 6] Figure 6A is a magnified view of the area enclosed by line 6A in Figure 4. Figure 6B is a magnified view of the area enclosed by line 6B in Figure 4. Figure 6C is a magnified view of the area enclosed by line 6C in Figure 4. Figure 6C is a magnified view of the area enclosed by line 6C in Figure 4. [Figure 7] This is an enlarged view of the area enclosed by line 7 in Figure 1B. [Modes for carrying out the invention]

[0010] <Examples> The example will be described based on the attached diagram. In the diagram, Fr indicates the front, Rr the back, Le the left, Ri the right, Up the top, and Dn the bottom.

[0011] Refer to Figure 1. Hereinafter, an example will be given in which the resin molded product according to this disclosure is used as a light fixture 10 installed in the instrument panel In of a vehicle.

[0012] Refer to Figures 2 and 3. This light fixture 10 comprises a first light guide 20 (light guide) and a second light guide 30 into which light from a light source (see arrow L) can be incident, a light emitter 40 that can emit light when incident from the first light guide 20 and the second light guide 30, a decorative layer 11 provided on the back surface 43 of the light emitter 40 and capable of decorating the light emitter 40, and a base material 50 that supports the light emitter 40, the first light guide 20 and the second light guide 30.

[0013] (Manufacturing method of the light fixture 10) The light fixture 10 is a resin molded product formed by heating and melting plastic resin and injecting it into a mold. The first light guide 20, the second light guide 30, and the light emitter 40 are formed from the same resin material, but the materials for each can be selected as appropriate, and different materials may be used. A detailed explanation of the manufacturing method of the light fixture 10 is omitted.

[0014] (Luminous element 40) The light-emitting body 40 is plate-shaped, and its outer shape is approximately rectangular. The shape of the light-emitting body 40 can be changed as appropriate. The surface 41 of the light-emitting body 40 faces into the vehicle interior and is a surface that can be seen by the vehicle's occupants.

[0015] The side surface 45 of the light-emitting body 40 has a first longitudinal side surface 46 extending in its longitudinal direction (left-right direction), a second longitudinal side surface 47 located opposite the first longitudinal side surface 46, a first short side surface 48 extending in the short direction (up-down direction) of the light-emitting body 40, and a second short side surface 49 located opposite the first short side surface 48.

[0016] The first longitudinal side surface 46 is linear and is also an incident surface on which light from the first light guide 20 can be incident. The second longitudinal side surface 47 is curved and is also an incident surface on which light from the second light guide 30 can be incident.

[0017] The distance between the first longitudinal side surface 46 and the second longitudinal side surface 47 gradually widens as it goes from the first short side surface 48 to the second short side surface 49 (the side opposite to the side where the light L from the light source is incident). That is, the second short side surface 49 is longer than the first short side surface 48.

[0018] (The first light guide 20) Refer to FIG. 4. The first light guide 20 is a linear member along the first longitudinal side surface 46 of the light emitter 40, and its cross section is rectangular. Hereinafter, the side (right side) where the light L from the light source is incident is taken as the base end, and the opposite side (left side) is taken as the tip end.

[0019] (The first air layer 21) The emission surface 20a of the first light guide 20 is separated from the first longitudinal side surface 46 (incident surface) of the light emitter 40 so as to face each other through the first air layer 21. The part of the first light guide 20 that constitutes the first air layer 21 is taken as the first main body part 22.

[0020] Furthermore, the first light guide 20 has a first tip part 23 that protrudes from the tip of the first main body part 22 beyond the second short side surface 49, and a first base part 24 that protrudes from the base end of the first main body part 22 beyond the first short side surface 48. That is, the first light guide 20 is arranged so as to protrude from the first longitudinal side surface 46.

[0021] (The second light guide 30) The second light guide 30 is a gently curved member along the second longitudinal side surface 47 of the light emitter 40, and its cross section is rectangular.

[0022] (The second air layer 3l) The emission surface 30a of the second light guide 30 is separated from the second longitudinal side surface 47 (incident surface) of the light emitter 40 so as to face each other through the second air layer 31. The part of the second light guide 30 that constitutes the second air layer 31 is taken as the second main body part 32.

[0023] Furthermore, the second light guide 30 has a second tip portion 33 that protrudes from the tip of the second main body portion 32 beyond the second short side surface 49, and a second base portion 34 that protrudes from the base end of the second main body portion 32 beyond the first short side surface 48. That is, the second light guide 30 is positioned so as to extend beyond the second long side surface 47.

[0024] (Light-emitting body side support part 51) Refer to Figures 3 and 5. The base material 50 has a light-emitting side support portion 51 that supports the light-emitting body 40. The light-emitting side support portion 51 is, for example, a substantially rectangular frame-shaped portion formed along the peripheral edge 44 on the back surface 43 side of the light-emitting body 40 (in this embodiment, the back surface of the decorative layer 11).

[0025] The light-emitting body side support portion 51 has a first longitudinal portion 52 along the first longitudinal side surface 46 of the light-emitting body 40, a second longitudinal portion 53 along the second longitudinal side surface 47 of the light-emitting body 40, a first short portion 54 along the first short side surface 48 of the light-emitting body 40, and a second short portion 55 along the second short side surface 49 of the light-emitting body 40. Each of the first longitudinal portion 52 to the second short portion 55 has ribs 52a to 55a.

[0026] (Decorative layer 11) Refer to Figure 3. The decorative layer 11 is, for example, a film, and can be used to decorate the light-emitting element 40 when the light-emitting element 40 is transparent. The decorative layer 11 is sandwiched between the light-emitting element side support part 51 and the light-emitting element 40. Note that the decorative layer 11 is not required.

[0027] (Light guide side support part 60, 70) Refer to Figures 3 and 4. The base material 50 has a first light guide side support portion 60 (light guide side support portion) that supports the first light guide 20. The first light guide side support portion 60 includes a first tip support portion 61 that supports the first tip portion 23 of the first light guide 20, and a first base end support portion 62 that supports the first base end portion 24 of the first light guide 20.

[0028] The base material 50 has a second light guide side support portion 70 (light guide side support portion) that supports the second light guide 30. The second light guide side support portion 70 includes a second tip support portion 71 that supports the second tip portion 33 of the second light guide 30, and a second base end support portion 72 that supports the second base end portion 34 of the second light guide 30.

[0029] (Connection part 80) Refer to Figures 4 and 5. The substrate 50 has four connecting parts 80 that connect the respective light guide side support parts 60, 70 and the light emitter side support part 51.

[0030] Refer to Figure 6A. The first tip support portion 61 and the upper end of the second short portion 55 (the end on the first light guide 20 side) are connected by the first tip connection portion 81. When viewed from the direction facing the surface 41 of the light emitter 40, the first tip connection portion 81 is positioned so as not to overlap with the first air layer 21.

[0031] Refer to Figure 6B. The first base end support portion 62 is connected to the upper end of the first short portion 54 (the end on the first light guide 20 side) by the first base end connection portion 82. The first base end connection portion 82 is positioned so as not to overlap with the first air layer 21.

[0032] Refer to Figure 6C. The second tip support portion 71 is connected to the lower end of the second short portion 55 (the end on the second light guide 30 side) by the second tip connecting portion 83. The second tip connecting portion 83 is positioned so as not to overlap with the second air layer 31.

[0033] Refer to Figure 6D. The first base support portion 62 and the lower end of the first short portion 54 (the end on the second light guide 30 side) are connected by a second base connection portion 84. The second base connection portion 84 is positioned so as not to overlap with the second air layer 31.

[0034] To summarize the above, it can be said that the first main body 22, which constitutes the first air layer 21, and the second main body 32, which constitutes the second air layer 31, are not supported by the base material 50.

[0035] (Support member 90) Refer to Figures 1A and 1B. The luminaire 10 is attached to the instrument panel In via a support member 90 that supports the luminaire 10. The support member 90 can also be described as an adapter for attaching the luminaire 10 to the instrument panel In. The support member 90 is a frame-shaped member that surrounds the surface 41 of the light-emitting element 40 so that only the light-emitting element 40 is exposed, and covers the base material 50, the first light guide 20, and the second light guide 30. The luminaire 10 may also be attached directly to the instrument panel In without using the support member 90. In this case, the base material 50 should be provided with appropriate mounting parts for the instrument panel In, such as bosses.

[0036] (Step portion 42 of the light-emitting body 40) Refer to Figures 2 and 3. The periphery of the surface 41 of the light-emitting body 40 has a stepped portion 42 formed in a stepped shape. Refer to Figure 7. The stepped portion 42 has a stepped bottom surface 42a facing the same direction as the surface 41 of the light-emitting body 40, and a stepped side surface 42b facing in a direction substantially perpendicular to the bottom surface 42a.

[0037] The inner circumferential side surface 91 of the support member 90 surrounds the stepped portion side surface 42b (the support member 90 can also be called a surrounding member). The inner circumferential edge 92a of the back surface 92 of the support member 90 is in contact with the bottom surface 42a of the stepped portion. The surface surface 93 of the support member 90 is located on the same plane as the surface surface 41 of the light-emitting element 40.

[0038] (Effects of the example) Refer to Figures 2 and 3. The first light fixture 10 (resin molded product) is, A first light guide 20 (light guide) into which light can be incident and which has an exit surface 20a, The first light guide 20 has an incident surface (first longitudinal side surface 46) into which light emitted from the exit surface 20a can be incident, and the light emitter 40 is capable of emitting light when light is incident from the first longitudinal side surface 46, A base material 50 having first light guide side support parts 60, 60 that support the first light guide 20, and a light emitter side support part 51 that supports the light emitter 40, is integrally formed. The emission surface 20a of the first light guide 20 and the incident surface (first longitudinal side surface 46) of the light emitter 40 are separated so as to face each other via the first air layer 21.

[0039] The boundary between the first light guide 20 and the light emitter 40 is clearly defined by the first air layer 21. Therefore, light is reflected repeatedly within the first light guide 20, making it possible to illuminate a greater distance. The materials of the first light guide 20 and the light emitter 40 are not limited to different materials; they can be the same, and no light diffusing material is required. The first light guide 20 and the light emitter 40 are supported by a base material 50 that fixes both of them. The first light guide 20 and the light emitter 40 can be supported with a simple structure. As a result, a lighting fixture 10 with reduced manufacturing costs can be provided.

[0040] In addition, if claws or bosses are provided on the base material 50, it becomes easier to attach the lighting fixture 10 to the instrument panel In.

[0041] The shapes of the first light guide 20, the light emitter 40, and the substrate 50 are not specified. Furthermore, a second light guide 30 may be used instead of the first light guide 20.

[0042] Refer to Figure 5. Secondly, in the first luminaire 10, The light-emitting element side support portion 51 is frame-shaped and formed along the peripheral edge 44 of the back surface 43 of the light-emitting element 40.

[0043] Compared to the case where a plate-shaped light-emitting support part 51 is provided that covers the entire back surface 43 of the light-emitting element 40, the light fixture 10 can be made lighter. As a result, light can pass through the inside of the light-emitting element 40, making it visible to the occupants, and the design freedom when decorating the light-emitting element 40 is increased.

[0044] Refer to Figures 6A to 6D. Thirdly, in the first or second luminaire 10, The base material 50 has a connecting portion 80 that connects the light guide side support portion 60, 70 and the light emitter side support portion 51. When viewed from a direction opposite to the surface 41 of the light-emitting element 40, the connecting portion 80 is positioned so as not to overlap with the air layer 21.

[0045] Light entering the incident surface (first longitudinal side surface 46) of the light-emitting body 40 from the exit surface 20a of the first light guide 20 is less likely to be absorbed (attenuated) by the connection portion 80 of the substrate 50, allowing more light to be incident on the light-emitting body 40 while illuminating it over a greater distance. The same applies to the second light guide 30.

[0046] Refer to Figure 3. Fourth, in the first to third lighting fixtures 10, The first light guide 20 and the light emitter 40 are made from the same material. Compared to the case where the first light guide 20 and the light-emitting element 40 are molded from different materials, manufacturing costs can be reduced.

[0047] Fifth, in the first to fourth luminaires 10, The back surface 43 of the light-emitting element 40 is provided with a decorative layer 11 (film) that can be used to decorate the light-emitting element 40.

[0048] The decorative layer 11 allows for decoration such as adding color or patterns to the light-emitting body 40. For example, if the light-emitting body 40 is transparent, the decorative layer 11 can prevent the interior from being seen.

[0049] Refer to Figures 3 and 4. Sixth, in the fifth luminaire 10, The light-emitting element side support portion 51 is frame-shaped and formed along the peripheral edge 44 of the back surface 43 of the light-emitting element 40. The light-emitting support portion 51 and the light-emitting body 40 are separated by a decorative layer 11.

[0050] The base material 50 has a support portion for the light-emitting element 40, and the decorative layer 11 can be supported using the light-emitting element 40.

[0051] Seventh, the first to sixth luminaires 10 are, In addition to the first light guide 20, it is equipped with a second light guide 30. The first light guide 20 and the second light guide 30 are positioned so as to sandwich the light-emitting body 40.

[0052] In other words, the second light guide 30 is positioned on the opposite side of the first light guide 20. Light is incident on the light-emitting element 40 from both sides, which increases the brightness of the lamp 10 (light-emitting element 40).

[0053] Eighth, in the seventh luminaire 10, The first light guide 20 and the second light guide 30 are arranged along the longitudinal direction (left-right direction) of the light emitter 40.

[0054] Compared to the case where the first light guide 20 and the second light guide 30 are arranged along the first short side surface 48 and the second short side surface 49 of the light-emitting body 40, the brightness of the light-emitting body 40 can be further increased.

[0055] Refer to Figure 7. If the stepped portion 42 is not formed, the inner edge 92a of the back surface 92 of the support member 90 will overlap the surface 41 of the light-emitting body 40. The light emitted by the first light guide 20 will easily leak through the gap where the surface 41 and the edge 92a overlap.

[0056] In this embodiment, the edge of the surface 41 of the light-emitting element 40 has a stepped portion 42 formed in a stepped shape around its entire circumference. The inner side surface 91 of the support member 90 surrounds the stepped portion side surface 42b. The inner edge 92a of the back surface 92 of the support member 90 is in contact with the bottom surface 42a of the stepped portion. That is, for the light emitted by the first light guide 20 to reach the passenger compartment, it must pass through the gap between the inner edge 92a and the bottom surface 42a of the stepped portion, as well as the gap between the side surface 91 and the stepped portion side surface 42b. Because the path through which the light travels to the passenger compartment is long and L-shaped, leakage of light emitted by the first light guide 20 can be suppressed. Furthermore, the surface 41 of the light-emitting element 40 can be made flush with the surface 93 of the support member 90, improving the aesthetic appearance.

[0057] If the support member 90 is not provided, the edge 97 of the hole in the instrument panel In may surround the side surface 42b of the stepped portion, the bottom surface 42a of the stepped portion may contact the back surface 98 of the instrument panel In, and the surface 41 of the light-emitting element 40 may be flush with the design surface 99 of the instrument panel In.

[0058] Furthermore, the present invention is not limited to the examples provided, provided that it achieves the intended function and effect. Moreover, the elements constituting the examples can be combined as appropriate. [Explanation of symbols]

[0059] 10...Lighting (resin molded product) 11…Decorative layer 20...First light guide (light guide), 20a...Emission surface of the first light guide 21...First air layer 30…Second light guide 31...Second air layer, 30a...Emission surface of the second light guide 40... Luminous body 41... Surface of the light-emitting object 43... The back side of the light-emitting object 44... Periphery of the back surface of the light-emitting object 46…First longitudinal side (incident surface of the light-emitting element) 47...Second longitudinal side (incident surface of the light-emitting element) 50...Base material 51... Light-emitting body side support part 60...First light guide side support part 70…Second light guide side support part 80...Connection part

Claims

1. A light guide that allows light to enter and has an exit surface, A light-emitting body having an incident surface into which light emitted from the light-emitting surface of the light guide can be incident, and which is capable of emitting light when light is incident from the incident surface, A substrate having a light guide side support portion that supports the light guide and a light emitter side support portion that supports the light emitter is integrally formed. The light-emitting surface of the light guide and the incident surface of the light-emitting body are separated from each other with an air layer in between. The substrate has a connecting portion that connects the light guide side support portion and the light emitter side support portion. The connecting portion is positioned such that it does not overlap with the air layer when viewed from a direction opposite to the surface of the light-emitting body. The air layer is open toward the back side of the light-emitting element in the resin molded product.

2. The light-emitting element side support portion is frame-shaped and formed along the periphery of the back surface of the light-emitting element. The resin molded article according to claim 1.

3. The light guide and the light emitter are formed from the same material. The resin molded article according to claim 1.

4. A decorative layer capable of decorating the light-emitting body is provided on the back surface of the light-emitting body. The resin molded article according to claim 1.

5. The light-emitting element side support portion is frame-shaped and formed along the periphery of the back surface of the light-emitting element. The light-emitting element side support portion and the light-emitting element are separated by the decorative layer. The resin molded article according to claim 4.

6. In addition to the light guide body, a second light guide body is provided. The light guide and the second light guide are arranged so as to sandwich the light emitter. A resin molded article according to any one of claims 1 to 5.

7. The light guide and the second light guide are arranged along the longitudinal direction of the light emitter. The resin molded article according to claim 6.

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