Tool for welding a light pane to a housing of a motor vehicle light

Abstract

A tool for welding a light pane to a housing of a motor vehicle light, the tool comprising a base body and at least one heating element arranged on the base body, wherein the heating element is displaceable relative to the base body between an idle position and a welding position.

Claims

1. A tool for welding a light pane to a housing of a motor vehicle light, the tool comprising: a base body; and at least one heating element arranged on the base body, wherein the heating element is displaceable relative to the base body between an idle position and a heating position, wherein the base body has a substantially plate-shaped design with a bottom side, wherein a z-direction is defined by the surface normal of the bottom side and an x-direction is defined by a tangent to the bottom side, and wherein the heating element is arranged on the bottom side and is linearly displaceable in a displacement direction, wherein the displacement direction corresponds to the x-direction, or wherein the projection of the displacement direction onto the x-direction and onto the z-direction has non-vanishing components, and wherein the bottom side of the base body has an inclined partial surface, wherein the projection of the surface normal of the partial surface onto the x-direction and onto the z direction has non-vanishing components, and wherein the heating element is accommodated on the inclined partial surface.

2. The tool according to claim 1, wherein a second heating element is accommodated on the bottom side, wherein the contour of a joining surface of the housing is reproduced by the heating element and the second heating element when the heating element is displaced into the heating position.

3. The tool according to claim 2, wherein the heating element is positioned closer to the second heating element in the heating position than when the heating element is in the idle position.

4. The tool according to claim 1, wherein the heating element comprises a guide body and a heating resistor accommodated thereon, wherein the guide body is arranged displaceable on the base body, and wherein the guide body has an angled and/or curved shape.

5. The tool according to claim 1, wherein the tool comprises a pneumatic cylinder or a servomotor, wherein the heating element is displaced via the pneumatic cylinder or via the servomotor.

6. The tool according to claim 1, wherein the heating element is slidably displaceable in the x-direction.

7. The tool according to claim 1, wherein a portion of the bottom side of the base body is flat and another portion of the bottom side of the base body has the inclined partial surface.

8. A tool for welding a light pane to a housing of a motor vehicle light, the tool comprising: a base body; and at least one heating element arranged on the base body, wherein the heating element is displaceable relative to the base body between an idle position and a heating position, and wherein the base body has a substantially plate-shaped design with a bottom side, wherein a z-direction is defined by the surface normal of the bottom side and an x-direction is defined by a tangent to the bottom side, and wherein the heating element is arranged on the bottom side and is linearly displaceable in a displacement direction, wherein the displacement direction corresponds to the x-direction, or wherein the projection of the displacement direction onto the x-direction and onto the z-direction has non-vanishing components, wherein a second heating element is accommodated on the bottom side, wherein the contour of a joining surface of the housing is reproduced by the heating element and the second heating element when the heating element is displaced into the heating position, and wherein a third heating element, via which the contour of a joining surface of the light pane is reproduced, is arranged on a top side of the base body opposite the bottom side.

9. A device for welding a light pane to a housing of a motor vehicle light, the device comprising: a lower receiving tool for the housing; an upper receiving tool for the light pane; a welding tool; a lifting device for moving the lower receiving tool and the upper receiving tool into a warming position and into a welding position; and a device for moving the welding tool into a joining plane between the lower receiving tool and the upper receiving tool, wherein the welding tool comprises a base body and at least one heating element arranged on the base body, wherein the heating element is displaceable relative to the base body between an idle position and a heating position, and wherein the base body has a substantially plate-shaped design with a bottom side, wherein a z-direction is defined by the surface normal of the bottom side and an x-direction is defined by a tangent to the bottom side, and wherein the heating element is arranged on the bottom side and is linearly displaceable in a displacement direction, wherein the displacement direction corresponds to the x-direction, or wherein the projection of the displacement direction onto the x-direction and onto the z-direction has non-vanishing components.

10. The device according to claim 9, wherein the lower receiving tool comprises a rigid connecting piece, the rigid connecting piece being the device for moving the welding tool into the joining plane, wherein rigid connecting piece moves the heating element on the welding tool into the heating position when the lower receiving tool is moved into the warming position.

11. A method for welding a light pane to a housing of a motor vehicle light by a device according to claim 10, the method comprising: receiving the housing in the lower receiving tool in a starting position and the light pane in the upper receiving tool; moving the welding tool into the joining plane between the housing and the light pane, wherein the bottom side of the base body faces a joining surface of the housing, an upper side of the base body faces a joining surface of the light pane, and the heating element is in the idle position; raising the lower receiving tool and lowering the upper receiving tool into the respective warming position, wherein the heating element is linearly moved into the heating position by the rigid connecting piece; warming and plasticizing the joining surfaces of the housing and the light pane by the heating element; lowering the lower receiving tool and raising the upper receiving tool out of the respective warming position, wherein the heating element is linearly moved into the idle position by means of gravity; retracting the welding tool; raising the lower receiving tool and lowering the upper receiving tool into the welding position in which the joining surfaces of the housing and the light pane are pressed against one another under a joining pressure, and waiting for the joining surfaces to cool down; lowering the lower receiving tool and raising the upper receiving tool out of the welding position; and removing a welded unit comprising the housing and the light pane.

12. A method for welding a light pane to a housing of a motor vehicle light by a device according to claim 9, the method comprising: receiving the housing in the lower receiving tool and the light pane in the upper receiving tool; moving the welding tool into the joining plane between the housing and the light pane, wherein the bottom side of the base body faces a joining surface of the housing, an upper side of the base body faces a joining surface of the light pane, and the heating element is in the idle position; raising the lower receiving tool and lowering the upper receiving tool into the respective warming position; linearly moving the heating element into the heating position; warming and plasticizing the joining surfaces of the housing and the light pane by the heating element; linearly moving the heating element into the idle position; lowering the lower receiving tool and raising the upper receiving tool out of the respective warming position; retracting the welding tool; raising the lower receiving tool and lowering the upper receiving tool into the welding position in which the joining surfaces of the housing and the light pane are pressed against one another under a joining pressure, and waiting for the joining surfaces to cool down; lowering the lower receiving tool and raising the upper receiving tool out of the welding position; and removing a welded unit comprising the housing and the light pane.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:

(2) FIG. 1 shows a cross-sectional view through a section of a two-part rear light with welding joints with limited access;

(3) FIGS. 2a and 2b show plan views of a welding tool of the invention; and

(4) FIGS. 3a and 3b show cross-sectional views through sections of a device of the invention and a rear light housing accommodated thereon.

DETAILED DESCRIPTION

(5) In order to illustrate the object on which the invention is based, FIG. 1 shows a cross-sectional view through a section of a two-part rear light with welding joints 45, 45 with limited access. The two-part rear light comprises fender light A and trunk lid light B, each of which has a light housing 4, 4, a light pane 5, 5, and a lighting component 7, 7. The sections of light panes 5, 5, extending at the top in the plane of the drawing, represent the back end of rear light segments A and B; the cross section shown in FIG. 1 therefore shows a horizontal sectional plane.

(6) In modern rear lights, there are design requirements for the smallest possible distance AB between the light functions, so that in the warm image of the rear light, i.e., when the light functions are turned on, the light impression is as spatially homogeneous as possible and also does not have a highly visible interruption in the transition area between fender light A and trunk lid light B. To minimize the distance AB, lighting components 7, 7 should be disposed in housings 4, 4 such that in the area of light panes 5, 5 they almost come into physical contact with light panes 5, 5.

(7) Welding joints 45, 45 between housings 4, 4 and light panes 5, 5 would thus be almost covered by lighting components 7, 7. The distance between welding joints 45, 45 and the rearward sections of light panes 5, 5, extending at the top in the plane of the drawing, is typically up to 40 mm in order to ensure visibility of the light functions even when the rear light is viewed from the side. When the joining surfaces are plasticized by means of thermal radiation, the distance between the joining surfaces in welding joints 45, 45 shown here and the heating elements used is typically 2 mm. Infrared heating elements according to the prior art comprise a wire-shaped or band-shaped heating resistor which is accommodated in a guide body. The thickness of such heating elements is substantially greater than the thickness of light panes 5, 5. Thus, in the case shown, severe limitation of the accessibility of the housing-side joining surfaces for a corresponding heating element arises due to the protruding lighting components 7, 7, even when a welding process based on contactless heating is used. Moving a heating element toward the housing-side joining surfaces by means of a straight lifting movement along a direction running vertically from top to bottom in the plane of the drawing, as is common in prior art welding devices, would not be possible here up to the required working distance of about 2 mm, because a collision of the heating element with sections of a lighting component 7, 7, said sections protruding beyond the joining surfaces, would occur first. Consequently, welding joints 45, 45, shown in FIG. 1, cannot be produced with welding tools or welding devices from the prior art; the object underlying the present invention is derived from this fact.

(8) FIGS. 2a and 2b show top views along the z-direction z of bottom side 10 of a welding tool 100 of the invention, which comprises the plate-shaped base body 1 as well as displaceable heating element 2 and rigid heating element 2. Heating elements 2, 2 comprise guide bodies 21, 21 and heating resistors 22, 22 accommodated thereon. Heating resistors 22, 22 formed here of corrugated, metallic strips with typical dimensions of 4 mm wide and 0.8 mm thick, which are designed to emit medium-wave infrared radiation when energized. Heating resistors 22, 22 are embedded in suitably dimensioned recesses on the end face of guide bodies 21, 21. The cross section of guide body 21 of rigid heating element 2 can be formed rectangular or trapezoidal; its flank height, i.e., the distance in the z-direction z between heating resistor 22 and the bottom side 10 of base body 1, is up to 50 mm. The cross section of guide body 21 of displaceable heating element 2 is L-shaped, wherein in the view shown here the bottom side of one leg of the L can be seen. Heating element 2 can be displaced along the x-direction x, for which purpose guide body 21 is received, for example, on rail-like sliding guides 13 on bottom side 10 of base body 1.

(9) FIG. 2a shows the position of displaceable heating element 2 in its idle position, in which heating element 2 is spaced apart from rigid heating element 2 in the x-direction x. In this position, in the method of the invention, the approach of welding tool 100 and the light housing to be welded takes place along the z-direction z. A lighting component part, disposed in the light housing (see FIG. 1) and protruding in sections over the joining surface, can pass without collision through the gap between displaceable heating element 2 and rigid heating element 2.

(10) FIG. 2b shows the position of displaceable heating element 2 in its heating position, in which heating element 2 abuts rigid heating element 2, so that the course of the two heating resistors 22, 22 simulates the contour of the joining surface of the light housing to be welded.

(11) In FIGS. 3a and 3b, cross-sectional views through sections of a welding device 200 of the invention with a welding tool 100 and an accommodated housing 4 of a fender light A are shown. Welding tool 100 comprises the substantially plate-shaped base body 1, the bottom side 10 of which has the inclined partial surface 12 on which guide body 21 of heating element 2 is displaceably received. Upper heating element 3, comprising guide body 31 and heating resistor 32 and provided for warming the joining surface of an associated light pane, is arranged on top side 11 of base body 1. Welding tool 100 is located in the joining plane between housing 4 and the light pane. The light pane and the upper receiving tool, receiving it, of device 200 are not shown here. Housing 4 with lighting component 7 disposed therein is received in the lower receiving tool of device 200, the lower receiving tool not being shown here.

(12) FIG. 3a shows the displaceable heating element 2 in the idle position, in which it is held by gravity. Joining surface 40 of housing 4 is brought closer to heating resistor 22 by means of a lifting movement along the z-direction z of the lower receiving tool, wherein rigid connecting piece 6, disposed on the lower receiving tool, is also moved accordingly in the z-direction z. Connecting piece 6 fulfills the function of a driver and from the point in time at which it comes into contact with guide body 21, heating element 2 is displaced along the inclined partial surface 12 when the lower receiving device is raised further. During the approach of housing 4 in the z-direction z, heating element 2 is therefore moved laterally to joining surface 40 by a simultaneous sliding movement with a movement component in the x-direction x, wherein the section of lighting component 7 protruding in the manner of a projection over joining surface 40 is more or less bypassed.

(13) In FIG. 3b, the lower receiving tool is in the warming position and displaceable heating element 2 is in the heating position; i.e., joining surface 40 and heating resistor 22 are suitably spaced from one another in the z-direction z and suitably aligned with one another in the x-direction x so that the warming and plasticizing of joining surface 40 can take place. When the lower receiving tool is subsequently lowered, the contact between guide body 21 and connecting piece 6 is released, so that guide body 21 slides down the inclined partial surface 12 under the influence of gravity until the heating element has returned to the idle position. Accordingly, when the lower receiving tool is lowered, heating element 2 moves along the same trajectory as when it is raised, so that no collision can therefore occur between heating element 2 and the protruding lighting component 7 during lowering as well.

(14) As an alternative to the use of a connecting piece 6 shown here, heating element 2 can also be displaced between the idle position and the heating position by means of a separate drive on welding tool 100, for example, by means of pneumatics or a servomotor.

(15) The invention is not limited in its implementation to the preferred exemplary embodiment described above. Rather, a number of variants are conceivable which make use of the shown solution even in the case of fundamentally different embodiments. All features and/or advantages arising from the claims, the description, or the drawings, including structural details, spatial arrangements, and method steps, can be essential to the invention both individually and in a wide variety of combinations.

(16) The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.