JPS6217351B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a mount in which a pair of filament coils are positioned at substantially the same height.

For example, a semi-shielded lamp used as a headlight for an automobile is constructed by attaching a halogen light bulb to a reflector whose front surface is covered with a lens. Such semi-shielded lamps usually have a two-beam configuration with a passing beam and a running beam, so the halogen bulb has a filament for the passing beam and a filament for the running beam inside the glass bulb. It is something that

By the way, since the tube wall temperature of such halogen light bulbs becomes extremely high when lit, they use high melting point glass such as quartz glass, and the sealing part is also used in general incandescent light bulbs. It does not use a glass flare stem, but uses a crush seal called a pinch seal. Therefore, in this type of halogen light bulb, it is necessary to align the four lead wires connected to a pair of filaments on the same straight line on a single crush sealing surface and crush seal. Since this sealed beam lamp requires strict light distribution characteristics, it is necessary to adjust the mutual positions of the filaments within the bulb with high precision.

Conventionally, in order to position a pair of filaments at approximately the same height, the applicant filed a patent application.
Japanese Patent Application No. 55-119292 (Japanese Unexamined Patent Publication No. 57-44963)
The method described below is adopted. That is, a mount head with four lead wire insertion holes arranged on the same straight line is prepared, and a pair of first lead wires are installed every other lead wire into the lead wire insertion holes of this mount head, and these lead wires are For example, a filament coil for a traveling beam is installed and connected between the tips of the . After the tips of these first lead wires are bent at a predetermined angle in a direction perpendicular to the parallel direction of the lead wires, these lead wires are pushed into the lead wire insertion holes. Next, a pair of second lead wires are attached to the remaining lead wire insertion holes, and a filament coil for a low beam is installed and connected between the tips of these lead wires. The tip portion is bent at a predetermined angle to the opposite side to the bending direction of the first lead wire. Thereafter, the first lead wire pushed into the lead wire insertion hole is returned to its original position, and the filaments are positioned at approximately the same height.

However, according to such a method, the first
Also, since it is necessary to bend the second lead wire, push it into the lead wire insertion hole, and then return it again, there is a risk that the lead wire may be bent or otherwise deformed. Even if the filaments can be positioned at the same height, the spacing between the filaments tends to vary, and the positional relationship between the filaments cannot be set with high precision.

The present invention has been made based on the above circumstances, and its purpose is to be able to position the filament coils at a constant height as well as the spacing between them; The present invention aims to provide a method for manufacturing a mount that can be performed with high precision.

That is, in order to achieve the above object, the method of the present invention positions the first and second filament coils at the same height, and then the portions of the first and second lead wires led out from the mounting head.
It is characterized in that the lead wires are clamped simultaneously from a direction orthogonal to the parallel direction of the lead wires, thereby plastically deforming the lead-out portions of the lead wires.

The present invention will be explained below based on an embodiment shown in the drawings.

First, in explaining the method of the present invention, the structure of the mounting head 1 used in this method will be explained with reference to FIGS. 1 and 2. In the figure, reference numeral 2 denotes the head body, and the head body 2 has four lead wire insertion holes 3a, 3b, and 4 along the same straight line.
a, 4b are formed through the lead wire insertion holes 3b, 4b, and an exhaust pipe insertion hole 5 is formed through the lead wire insertion holes 3b, 4a. And inside the head body 2,
Each lead wire insertion hole 3a, 3b and 4a, 4
Corresponding to b, chuck claws 6a, 6b and 7a,
7b is provided. These chuck claws 6a,
6b, 7a, 7b have one end facing the side surface of the head main body 2, and the other end facing the lead wire insertion holes 3a, 3b and 4a, 4b, and are connected to the other ends of the lead wire insertion holes 3a, 3b and 4a, 4b. Hole 3a, 3
b and 4a, 4b, the lead wire insertion hole 3
First lead wires 8a, 8b and second lead wires 9a, 9b, which are inserted alternately into a, 3b and 4a, 4b, are individually held.
and chuck claws 6a, 6b and 7a, 7b
is biased in the direction of clamping the lead wires 8a, 8b and 9a, 9b by a coil spring (not shown), and when one end of these is pushed in, the coil spring is compressed and the clamping is released. It's getting old.

Next, a method of manufacturing a halogen light bulb using such a mounting head 1 will be explained with reference to FIGS. 3a to 3.

First, insert the mount head 1 into the lead wire insertion hole 3.
a, 3b and 4a, 4b are fixed in the vertical direction, and one end of the chuck claws 6a, 6b is pushed into the head body 2. Next, the first lead wires 8a and 8 are inserted into the lead wire insertion holes 3a and 3b from above, respectively.
8b is inserted, and when the insertion tips of these lead wires 8a, 8b are led out by a predetermined length from the lower surface of the head main body 2, the pressure of the chuck claws 6a, 6b is released, and the first lead wires 8a, 8b are inserted. Attach and secure it to mount head 1. Next, the insertion tips of the first lead wires 8a, 8b are bent into a substantially U-shape to form tip hook portions 10, 10 thereon. Leg portion 1 of filament coil 11
2 and 12, and these tip hook parts 10,
10 by clamping the first lead wire 8
The filament coil 11 is installed and connected between the insertion tip portions a and 8b. Thereafter, by simultaneously bending the insertion ends of the first lead wires 8a, 8b at a predetermined angle in a direction orthogonal to the parallel direction of the lead wires 8a, 8b, the first lead wires 8a, 8b have bent portions. Form 13,13. Through the steps up to this point, the traveling beam mount 14 is completed. Next, one end of the chuck claws 6a, 6b is pushed in again, and at the same time, one end of the other chuck claws 7a, 7b is also pushed in. When the entire traveling beam mount 14 is pushed up toward the mount head 1 side, the chuck claws 6a, 6b
Release the pressure and connect the lead wire 8 of this mount 14.
Fix a and 8b to the mount head 1 again. Also, in synchronization with this work, other lead wire insertion holes 4
A pair of second lead wires 9 from above inside a and 4b
When the lead wires 9a and 9b are inserted and the insertion tips of these lead wires 9a and 9b are led out from the lower surface of the head main body 2 by a predetermined length, the pressure of the chuck claws 7a and 7b is released and the second lead wires 9a and 9b are inserted. , 9b are mounted and fixed on the mount head 1. Therefore, in this state, the insertion tips of the second lead wires 9a and 9b are connected to the filament coil 11 of the mount 14.
The first lead wires 8a, 8b and the second lead wires 9a, 9b are alternately located along the same straight line.

Next, the insertion tips of the second lead wires 9a and 9b are bent into a substantially U-shape, and the tip hook portions 1 are attached thereto.
5, 15 are formed, the leg portions 17, 17 of a filament coil 16 for a low beam, for example, are locked to these end hook portions 15, 15,
By clamping these tip hook portions 15, 15, the filament coil 16 is installed and connected between the insertion tip portions of the second lead wires 9a, 9b. After this, in this embodiment, the second lead wire 9
The insertion tip side of a, 9b is connected to the first lead wire 8.
The second lead wires 9a, 9b are bent at a predetermined angle in the opposite direction to the bending direction of the lead wires 9a, 9b to form bent portions 18, 18, thereby completing the mount 19 for the passing beam.

By subsequently pushing in one end of the chuck claws 6a, 6b, the first lead wires 8a, 8
b is released, and the traveling beam mount 14 pushed up toward the mount head 1 is returned to its original position, and the filament coil 11 for the traveling beam and the passing beam mount 14 are removed as shown in FIG. The filament coil 16 is placed in parallel with the filament coil 16 at substantially the same height.

In the process up to this point, if the first and second lead wires 8a, 8b and 9a, 9b are straight without bending, and are placed side by side on the same straight line with high precision, each filament coil At the same time as the heights of the filament coils 11 and 16 are aligned, the separation width l between the filament coils 11 and 16 is also set to a predetermined value. However, the first and second lead wires 8a, 8b and 9a, 9b are
If the filament coils 11 and 16 are bent or tilted as shown by the imaginary line in FIG.
6, the positional accuracy between them will deteriorate.

Therefore, in the embodiment according to the method of the present invention, after the filament coils 11 and 16 are positioned at the same height, the bent portions 13, 13 and 1 of the first and second lead wires 8a, 8b and 9a, 9b are
Connect the lead wires 8a, 8b and 9a, 9b to the lead wires 8a, 8b and 9a, 9b.
The clamping force is applied between a pair of clamping pressure heads 20 and 21 from a direction perpendicular to the parallel direction. The clamping pressure heads 20 and 21 of this embodiment have a protrusion 22 on one clamping pressure surface, and a recess 23 into which the protrusion 22 can fit into the other clamping surface.
The lead-out portions of the lead wires 8a, 8b and 9a, 9b are simultaneously clamped and pressed between the lead wires 8a, 8b and the recess 23 to plastically deform them, and a substantially U-shaped deformed portion 24 bulges outward at the lead-out portions. to form a bend.

Thereafter, the glass bulb 25 is placed over the mounts 14 and 19, and the bulb 2 is inserted through the exhaust pipe insertion hole 5 of the mount head 1.
5. Insert the exhaust pipe 26 into the tube. After the opening of this valve 25 is heated and softened, it is connected to the first and second lead wires 8a, 8b and 9a,
Crushing and sealing is performed from a direction perpendicular to the parallel direction of 9b. Therefore, the lead wires 8a, 8b and 9a, 9b are aligned on the same straight line and are sealed through the sealing portion 27. After this, the inside of the bulb 25 is evacuated, a predetermined gas is filled in the bulb 25, and the exhaust pipe 26 is tipped, thereby completing a halogen light bulb as shown in FIG.

According to such a manufacturing method, after aligning the filament coil 11 for the traveling beam and the filament coil 16 for the passing beam at substantially the same height, the first and second lead wires 8a, 8b and Since the lead-out portions of the filament coils 9a and 9b are forcibly deformed plastically through the pair of clamping heads 20 and 21, in the process up to aligning the heights of the filament coils 11 and 16, Even if the first and second lead wires 8a, 8b and 9a, 9b are bent or otherwise misaligned, the dimensional error between the filament coils 11, 16 due to this misalignment will be caused by the above-mentioned plastic deformation. It will be absorbed. As a result, the distance l between the filaments 11 and 16 can be adjusted to a predetermined value with high precision. Therefore, the pair of filament coils 11 and 16 can be positioned accurately, which is particularly useful for manufacturing products that require strict light distribution characteristics, such as halogen bulbs for automobile headlights. It becomes convenient.

Moreover, in this method, since the first and second lead wires 8a, 8b and 9a, 9b are plastically deformed, these lead wires 8a, 8b and 9a, 9b are deformed plastically.
Work hardening occurs, and therefore, when the halogen light bulb is completed, the lead wires 8a, 8b and 9a, 9b are prevented from wobbling, and the vibration resistance is greatly improved.

Note that the method of the present invention is not limited to the production of halogen light bulbs for headlamps, but can be applied to any mount formed by connecting a pair of filament coils at approximately the same height.

Further, in the above embodiment, the lead wires of both mounts are bent in opposite directions after the filament is installed, but the present invention is not limited to the above embodiment, and the lead wires of one mount are bent first. If the bending angle of the wire is increased, the lead wire of the other mount does not necessarily need to be bent.

The present invention described in detail above provides a pair of first and second
The first wires are installed and connected between the tips of the lead wires.
After aligning the filament coil and the second filament coil at approximately the same height, the portions of these lead wires led out from the mount head are simultaneously clamped from a direction perpendicular to the parallel direction of these lead wires. This is a method of manufacturing a mount in which parts are plastically deformed. According to this method, even if the first and second lead wires bend or otherwise shift in alignment during the process of aligning the filament coils at the same height, the lead wires Since the plastic deformation is forced into a fixed shape, the dimensional error between the filament coils due to the misalignment is eliminated by this deformation. Therefore, the distance between the filament coils can be kept constant, and the filament coils can be positioned with high precision. Moreover, since work hardening occurs in the first and second lead wires when the mount is completed, the wobbling of these lead wires is reduced, resulting in excellent effects such as significantly improved vibration resistance.

[Brief explanation of the drawing]

The drawings show one embodiment of the present invention, in which Fig. 1 is a perspective view of the mounting head, Fig. 2 is a side view, and Fig. 3 a.
It is a perspective view or a side view showing a working process in order. 1...Mount head, 3a, 3b, 4a, 4
b... Lead wire insertion hole, 8a, 8b... First lead wire, 9a, 9b... Second lead wire, 11...
...First filament coil (filament coil for passing beam), 24... Deformed part.

Claims (1)

[Claims] 1 Two pairs of lead wires are arranged alternately along the same straight line, and a filament coil is installed and connected between the tips of each pair of lead wires, so that these filament coils are at approximately the same height. In a method for manufacturing a mount located at At the same time, a first filament coil is installed and connected between the tips of these lead wires led out from the mount head, and the tip side of these first lead wires is connected to the parallel direction of these lead wires. After bending in the crossing direction, push this first lead wire into the lead wire insertion hole, then attach a pair of second lead wires to the remaining lead wire insertion holes of the mount head, and A second filament is installed and connected between the tips of the second lead wire, and then the first filament is inserted into the lead wire insertion hole.
By returning the lead wires to their original positions, the first and second filament coils are positioned at approximately the same height, and then the portions of the first and second lead wires extending from the mounting head are
By simultaneously applying pressure from a direction perpendicular to the parallel direction of these lead wires, the lead-out portion is plastically deformed to form a deformed portion here, and by this deformation, the interval between the first and second filament coils is predetermined. A method for manufacturing a mount, characterized in that the position is adjusted at set intervals.