Vehicle headlamp

Abstract

A vehicle headlamp (1) is provided with: a second light source (22) having a light emission surface (22s) that emits light toward the front side; and a reflector unit (30) that has a second opening (32h) from which the emission surface (22s) is exposed, and a second reflection part (32) that surrounds the second opening (32h) and that is disposed further forward than the emission surface (22s), the second reflection part (32) reflecting the light emitted from the emission surface (22s) forward, the second reflection part (32) being provided with a cutout (35), and the cutout (35) being formed in the cutout (35). And cutouts (35) which extend in the vertical direction from the left and right sides of at least one of the upper edge and the lower edge of the second opening (32h), and through which a part of the light emitted from the emission surface (22s) passes.

Description

Technical Field

[0001] The present invention relates to a vehicle headlamp. Background Art

[0002] There is known a vehicle headlamp including a light source and a reflector unit, the reflector unit being disposed on the front side of the light source and having an opening through which the light source is exposed. Patent Document 1 listed below discloses such a vehicle headlamp.

[0003] In the vehicle headlamp disclosed in the following patent document 1, the reflector unit has an opening surrounded by a reflecting portion and through which a low-beam light source is exposed, and another opening surrounded by another reflecting portion and through which a high-beam light source is exposed. Each reflecting portion reflects light from the light source exposed from the opening surrounded by each reflecting portion forward. Therefore, in the vehicle headlamp, a low-beam light distribution pattern and a high-beam light distribution pattern are formed by light emitted from the light source and reflected forward by the reflecting portion and light emitted from the light source and propagated forward without being reflected by the reflecting portion.

[0004] Patent Document 1: International Publication No. 2022 / 009683 Summary of the invention

[0005] The light emitted from the light source is generally diffused. As in the vehicle headlamp of the above-mentioned Patent Document 1, when the light source is exposed from the opening surrounded by the reflective portion, the reflective portion is located in front of the light source, so a part of the light from the light source is sometimes blocked by the reflective portion. Therefore, sometimes it is difficult for the light from the light source to enter the portion of the reflective portion that is outside the opening in the left-right direction and below or above the opening. If it is difficult for the light from the light source to enter such a portion of the reflective portion, dark areas are sometimes formed on the left and right sides of the light distribution pattern of the light emitted from the vehicle headlamp.

[0006] Therefore, an object of the present invention is to provide a vehicle headlamp capable of suppressing the formation of dark areas on both left and right sides of a light distribution pattern.

[0007] In order to achieve the above-mentioned purpose, the vehicle headlamp of the present invention is characterized in that it comprises: a light source, which has a light emitting surface facing the front side; a reflector unit, which has an opening for exposing the exit surface, and a reflecting portion arranged at a position closer to the front side than the exit surface and surrounding the opening, the reflecting portion reflects the light emitted from the exit surface forward, and a cutout is provided in the reflecting portion, which extends in the up-down direction from the left and right sides of at least one of the upper edge and the lower edge of the opening, respectively, for allowing a part of the light emitted from the exit surface to pass through.

[0008] The vehicle headlamp can make the light passing through the left cutout enter the portion of the reflector on the left side of the opening, and make the light passing through the right cutout enter the portion of the reflector on the right side of the opening. The left and right cutouts extend in the up-down direction from at least one of the upper edge and the lower edge of the opening, so the portion where the light passing through the cutout enters is located on the side of the cutout with the opening in the up-down direction as a reference, and is located on at least one side of the upper side and the lower side of the opening. Therefore, according to the vehicle headlamp, compared with the case where the above-mentioned cutout is not provided, it is possible to suppress the light from the light source from being difficult to enter the portion of the reflector that is on the outside of the opening in the left-right direction and on the lower side or the upper side of the opening. Therefore, according to the vehicle headlamp, compared with the above-mentioned case, it is possible to suppress the formation of dark areas on the left and right sides of the light distribution pattern of the emitted light.

[0009] A connection portion between an edge of each of the cutouts on a center side of the opening and an edge of the opening may be located outside of both ends of the emission surface in the left-right direction.

[0010] By forming such a structure, compared with the case where the connecting portion is located inwardly of both ends of the emission surface in the left-right direction, it is possible to suppress the left and right sides of the light distribution pattern of the light reflected on the side where the cutout is provided above and below the opening of the reflecting portion from becoming darker or the width of the light distribution pattern in the left-right direction from becoming narrower. Therefore, according to the vehicle headlamp, compared with the above case, it is possible to suppress the formation of dark areas on the left and right sides of the light distribution pattern of the emitted light.

[0011] The edge of each of the cutouts on the opposite side to the center side of the opening may be connected to the end of the edge of the opening in the left-right direction.

[0012] The front end portion of each of the cutouts may be curved so as to approach a center side of the opening in the left-right direction.

[0013] Alternatively, the vehicle headlamp may further include: a radiator having a mounting surface for mounting a substrate on which the light source is mounted; and a bracket abutting against the radiator from the rear side at a position lower than the mounting surface to fix the radiator, wherein the radiator is provided with a through hole for a screw, the through hole for the screw penetrating in the front-rear direction for insertion of a screw fixing the radiator to the bracket, and a contact surface of the radiator for which the screw abuts is located at a position rearward of a plane overlapping with the mounting surface.

[0014] When the vehicle headlamp includes a heat sink, the heat sink may be provided with a pin through-hole into which a pin provided on the bracket is inserted at a position below the screw through-hole.

[0015] When the vehicle headlamp includes a radiator, the radiator has a bottom plate including the mounting surface on a front main surface, and an upper edge of the bottom plate has inclined portions that are linearly inclined downward toward the outer side in the left-right direction at both ends in the left-right direction.

[0016] According to this vehicle headlamp, the weight of the radiator can be reduced compared to a case where the upper edge of the bottom panel is in a horizontal straight line shape.

[0017] As described above, according to the present invention, it is possible to provide a vehicle headlamp capable of suppressing the formation of dark areas on both left and right sides of a light distribution pattern. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a diagram schematically showing a vehicle headlamp according to an embodiment of the present invention.

[0019] Figure 2 It is a figure which shows the state which supported the lamp unit by the bracket.

[0020] Figure 3 This is an exploded perspective view of the lamp unit viewed diagonally from the front and above.

[0021] Figure 4 This is a three-dimensional view of the radiator viewed diagonally from the front and above.

[0022] Figure 5 This is a diagram showing a state in which the reflector unit is mounted on the heat sink as viewed from the front.

[0023] Figure 6 It is a magnified representation Figure 5 A diagram of a portion of the image containing a reflective portion.

[0024] Figure 7 It is along Figure 6 Cross-sectional view along line VII-VII.

[0025] Figure 8 It is a vertical cross-sectional view of the lamp unit.

[0026] Fig. 9 2 is a diagram showing a low-beam distribution pattern in the present embodiment.

[0027] Fig.10 2 is a diagram showing a high-beam light distribution pattern in the present embodiment. DETAILED DESCRIPTION

[0028] The following, with the attached Figure 1The following is an example of a method for implementing the vehicle headlamp of the present invention. The following example implementation is for easy understanding of the present invention and is not intended to limit the interpretation of the present invention. The present invention can be changed and improved without departing from its main purpose. In addition, the present invention can also appropriately combine the constituent elements of each embodiment of the following example. It should be noted that in the drawings referred to below, the dimensions of each component are sometimes changed for easy understanding.

[0029] Figure 1 This is a diagram schematically showing a vehicle headlamp of the present embodiment. The vehicle headlamp of the present embodiment is used for an automobile. The vehicle headlamp is generally arranged in the left and right directions in front of the vehicle. In this specification, "right" refers to the right side in the forward direction of the vehicle, and "left" refers to the left side in the forward direction of the vehicle. The left and right vehicle headlamps have the same structure except that the shapes are roughly symmetrical in the left and right directions. Therefore, the vehicle headlamp on one side is described below.

[0030] like Figure 1 As shown, the vehicle headlamp 1 of this embodiment includes a lamp unit 2 and a frame 3, and a bracket (not shown) as a main structure. Figure 1 is a side view of a vehicle headlamp 1. Figure 1 In the figure, the frame body 3 is shown in cross section for easy understanding.

[0031] The frame 3 includes a housing 3h and a front cover 3c as main structures. The front cover 3c allows light emitted from the lamp unit 2 to pass through. The housing 3h is configured as a box having an opening at the front, and the front cover 3c is fixed to the housing 3h in a manner of blocking the opening. In this way, a storage space surrounded by the housing 3h and the front cover 3c is formed in the frame 3, and the lamp unit 2 and a bracket supporting the lamp unit 2 are arranged in the storage space.

[0032] Figure 2 1 is a diagram showing a state where the lamp unit 2 is supported by the bracket. 2 is a diagram showing the lamp unit 2 and the bracket as viewed from the front side. Figure 2 As shown, the bracket 4 of the present embodiment is a substantially quadrilateral frame-shaped member having a through hole 4h. The lamp unit 2 is fixed and supported on the bracket 4 in a state where a portion of the lamp unit 2 is located on the front side of the bracket 4. It should be noted that the fixing of the lamp unit 2 to the bracket 4 will be described later. The bracket 4 is fixed to the frame 3 via a supporting mechanism not shown in the figure. Therefore, the lamp unit 2 is fixed to the frame 3 via the supporting mechanism and the bracket 4. Examples of the material constituting the bracket 4 include metals and the like.

[0033] Figure 3 This is an exploded perspective view of the lamp unit 2 viewed from the front and above. Figure 3As shown, the lamp unit 2 of the present embodiment includes a heat sink 10 , a substrate 20 , a reflector unit 30 , a projection lens 40 , a holder 50 , and a light shielding plate 60 as main components.

[0034] Figure 4 The radiator 10 is a three-dimensional view of the radiator 10 viewed from the front and obliquely above. The radiator 10 is made of a material with excellent heat dissipation properties, such as metal. Figure 3 and Figure 4 As shown, the heat sink 10 of the present embodiment includes a bottom plate 11 on which a substrate 20 is placed, a plurality of heat sinks 12 , and a plurality of mounting bosses 13 as main components.

[0035] The bottom plate 11 is a plate-shaped component having a main surface 11s located on the front side, and the main surface 11s includes a placement surface 11ps on which the substrate 20 is placed near the approximate center in the up-down direction. In the present embodiment, the placement surface 11ps is a flat surface that is oriented upward and inclined toward the rear side. In addition, the upper edge of the bottom plate 11 has inclined portions 11ue1 at both ends in the left-right direction that are linearly inclined toward the outer sides in the left-right direction and toward the lower side, and the portion between the two inclined portions 11ue1 is a substantially horizontal central portion 11ue2. Therefore, according to the vehicle headlamp 1 of the present embodiment, the weight of the radiator 10 can be reduced compared to the case where the upper edge of the bottom plate 11 is a horizontal straight line. It should be noted that the upper edge of the bottom plate 11 is not particularly limited, and for example, it can also be a substantially horizontal straight line as a whole.

[0036] The plurality of heat sinks 12 are arranged side by side on the main surface 11 s above the mounting surface 11 ps and on the main surface on the rear side of the base plate 11 .

[0037] The plurality of mounting bosses 13 are protrusions protruding forward from the main surface 11s. In the present embodiment, the mounting bosses 13 are provided on both left and right sides below the mounting surface 11ps and on both left and right sides above the mounting surface 11ps. The front end surface 13as of each mounting boss 13 is a flat surface, and the bottom plate 11 is provided with a screw through hole 14 extending from the front end surface 13as to the rear side of the bottom plate 11 and penetrating the bottom plate 11 in the front-rear direction.

[0038] In addition, the bottom plate 11 is provided with a through hole 15 for pins that penetrates in the front-back direction. In the present embodiment, two through holes 15 for pins are provided respectively on the lower side of the two mounting bosses 13 located on the lower side of the mounting surface 11ps and between the two mounting bosses 13 located on the upper side of the mounting surface 11ps. The two through holes 15 for pins located on the lower side of the two mounting bosses 13 located on the lower side of the mounting surface 11ps are located below each of the two mounting bosses 13 and are substantially circular. In addition, the two through holes 15 for pins located between the two mounting bosses 13 located on the upper side of the mounting surface 11ps are arranged in the left-right direction and are substantially in the shape of an elliptical track that is long in the upper direction.

[0039] The bracket 4 contacts the rear surface of the bottom plate 11 from the rear side. Figure 2 As shown, the pin 4p provided on the bracket 4 is inserted from the rear side into one of the two pin through holes 15 located on the upper side and the two pin through holes 15 located on the lower side. In addition, screws 81 are inserted from the front side into the four screw through holes 14, and the screws 81 are fixed to the screw holes (not shown) provided on the bracket 4, thereby fixing the heat sink 10 to the bracket 4. Therefore, the bracket 4 abuts against the bottom plate 11 of the heat sink 10 from the rear side at the lower side and the upper side of the mounting surface 11ps. In addition, the front end surface 13as of the boss 13 is a contact surface for the screw 81 that fixes the heat sink 10 to the bracket 4 to abut. In this embodiment, the front end surfaces 13as of the two mounting bosses 13 located on the lower side of the mounting surface 11ps are located at the rear side of the plane overlapping with the mounting surface 11ps, and the front end surfaces 13as of the two mounting bosses 13 located on the upper side of the mounting surface 11ps are located at the front side of the plane. It should be noted that in Figure 1 In the figure, the plane is represented by a dotted line. In addition, there is no restriction on the position of the front end face 13as in the front-to-back direction with respect to the plane. For example, the front end faces 13as of the two mounting bosses 13 located on the lower side of the mounting surface 11ps may also be located in front of the plane. In addition, there is no restriction on the number and position of the through holes 14 for screws and the through holes 15 for pins. For example, the mounting bosses 13 may be provided only on the lower side of the mounting surface 11ps, and the bracket 4 may abut against the radiator 10 from the rear side at a position on the lower side of the mounting surface 11ps. In addition, the through holes 15 for pins may not be provided on the radiator 10.

[0040] As described above, the substrate 20 is placed on the placement surface 11ps of the heat sink 10. Figure 3 As shown, a first light source 21 , a second light source 22 , and a connector 23 are mounted on the surface of the substrate 20 opposite to the heat sink 10 , and the light emitting surfaces of the first light source 21 and the second light source 22 face forward.

[0041] The first light source 21 emits light forming a low-beam light distribution pattern to the front side. The second light source 22 emits light forming a high-beam light distribution pattern to the front side together with the light emitted from the first light source 21. In the present embodiment, the first light source 21 and the second light source 22 are LED arrays composed of a plurality of LEDs (Light Emitting Diodes) arranged in the left-right direction, and the second light source 22 is located at a lower side than the first light source 21. The connector 23 is arranged at a lower side than the second light source 22. A circuit not shown in the figure is provided on the substrate 20, through which the connector 23 and the first light source 21 and the connector 23 and the second light source 22 are respectively connected. Power is supplied to the connector 23 from a power supply unit not shown in the figure. Therefore, power is supplied from the connector 23 to the first light source 21 and the second light source 22. In addition, the first light source 21 and the second light source 22 are not limited to LED arrays.

[0042] Figure 5 1 is a diagram showing a state where the reflector unit 30 is mounted on the heat sink 10 as viewed from the front side, and is a diagram showing a state where the reflector unit 30 is mounted on the heat sink 10 as viewed along the optical axis of the projection lens 40 described later. Figure 3 and Figure 5 As shown in FIG. 1 , the reflector unit 30 is arranged at a position closer to the front side than the substrate 20, and the substrate 20 is sandwiched between the reflector unit 30 and the heat sink 10. The reflector unit 30 of this embodiment is composed of a reflector 30a and a cover 30b connected to the left and right sides and the upper side of the reflector 30a, and the reflector 30a and the cover 30b are formed integrally. Figure 5 , the reflector 30a is surrounded by a dotted line. In the present embodiment, the cover 30b is fixed to the heat sink 10 by screws 82. As a result, the reflector unit 30 presses the substrate 20 toward the heat sink 10, and the substrate 20 is fixed to the heat sink 10. As a material constituting the reflector unit 30, for example, a plated metal can be cited, and the reflector unit 30 is formed by, for example, cutting and plating a metal part obtained by casting.

[0043] Figure 6 Yes Figure 5 FIG. 1 is an enlarged view of a portion including the reflection portion 30a, Figure 7 It is along Figure 6 The sectional view of line VII-VII in FIG. Figure 6 In the figure, in order to facilitate the observation of the first opening and the second opening of the reflector unit 30 described later, the first light source 21 and the second light source 22 are indicated by dotted lines. Figure 7 In the embodiment, the heat sink 10 is omitted, and an example of the optical path of the light emitted from the first light source 21 is indicated by a single-dot chain line, and an example of the optical path of the light emitted from the second light source 22 is indicated by a double-dot chain line. Figure 6 and Figure 7 As shown, the reflection portion 30 a of the present embodiment includes a first reflection portion 31 and a second reflection portion 32 located below the first reflection portion 31 .

[0044] The first reflecting portion 31 is arranged at a position closer to the front side than the exit surface 21s of the first light source 21, and has a first opening 31h for exposing the exit surface 21s in the front. Therefore, the first opening 31h is surrounded by the first reflecting portion 31. The first reflecting portion 31 reflects the light emitted from the exit surface 21s forward. In the present embodiment, the first opening 31h is in the shape of a horizontally long rectangular shape. In addition, the first reflecting portion 31 includes a first upper reflecting portion 31u extending from the upper edge of the first opening 31h to the upper side, a first lower reflecting portion 31d extending from the lower edge of the first opening 31h to the lower side, a first left reflecting portion 31l extending from the left edge of the first opening 31h to the left side, and a first right reflecting portion 31r extending from the right edge of the first opening 31h to the right side. Moreover, the lower surface 31us of the first upper side reflecting portion 31u is the upper edge of the first opening 31h, the upper surface 31ds of the first lower side reflecting portion 31d is the lower edge of the first opening 31h, the right side surface 31ls of the first left side reflecting portion 31l is the left edge of the first opening 31h, and the left side surface 31rs of the first right side reflecting portion 31r is the right edge of the first opening 31h.

[0045] The second reflecting portion 32 is arranged at a position closer to the front side than the exit surface 22s of the second light source 22, and has a second opening 32h in which the exit surface 22s is exposed in the front. Therefore, the second opening 32h is surrounded by the second reflecting portion 32. The second reflecting portion 32 reflects the light emitted from the exit surface 22s forward. In the present embodiment, the second opening 32h is in the shape of a horizontally long rectangular shape, and the width of the second opening 32h in the left-right direction is narrower than the width of the first opening 31h in the left-right direction. In addition, the second reflecting portion 32 includes: a second upper reflecting portion 32u, which extends from the upper edge of the second opening 32h to the upper side; a second lower reflecting portion 32d, which extends from the lower edge of the second opening 32h to the lower side; a second left reflecting portion 32l, which extends from the left edge of the second opening 32h to the left side; and a second right reflecting portion 32r, which extends from the right edge of the second opening 32h to the right side. Moreover, the lower surface 32us of the second upper side reflecting portion 32u is the upper edge of the second opening 32h, the upper surface 32ds of the second lower side reflecting portion 32d is the lower edge of the second opening 32h, the right side surface 32ls of the second left side reflecting portion 32l is the left edge of the second opening 32h, and the left side surface 32rs of the second right side reflecting portion 32r is the right edge of the second opening 32h.

[0046] In the present embodiment, the second upper reflector 32u is connected to the first lower reflector 31d of the first reflector 31 and is integrally formed, and the second upper reflector 32u and the first lower reflector 31d form a beam shaper BS having a shape that tapers toward the front end. Therefore, the upper surface of the beam shaper BS is the upper surface 31ds of the first lower reflector 31d, and the lower surface of the beam shaper BS is the lower surface 32us of the second upper reflector 32u. The front end BSe of the beam shaper BS has a shape that is consistent with the cut-off line in the low-beam distribution pattern described later, and has an inclined portion BSea that is inclined upward from the left side to the right side at the approximate center in the left-right direction. In addition, a protrusion 31db that protrudes upward is provided at a position on the upper surface 31ds that is on the right side of the inclined portion BSea. In addition, the width of the first opening 31h on the right side of the inclined portion BSea in the vertical direction widens from the left side to the right side. It should be noted that the protrusion 31db may not be provided on the upper surface 31ds. In addition, the width of the first opening 31h in the vertical direction is not limited, and for example, may be substantially constant in the horizontal direction.

[0047] The second lower side reflection portion 32d is provided with a cutout 35, and the cutout 35 extends downward from the left and right sides of the upper surface 32ds as the lower edge of the second opening 32h. Therefore, it can be understood that the second opening 32h exposed by the exit surface 22s includes these cutouts 35. A part of the light emitted from the exit surface 22s passes through each cutout 35. In the present embodiment, the shape of the left and right cutouts 35 is a substantially left-right symmetrical shape, but this is not limited.

[0048] The connection portion 35e1c between the edge 35e on the center side of the second opening 32h in each cutout 35 and the edge of the second opening 32h is located outside the two ends of the emission surface 22s of the second light source 22 in the left-right direction. In the present embodiment, as described above, the second light source 22 is composed of an LED array, so the end on the right side of the emission surface 22s of the second light source 22 is the end on the right side of the emission surface of the rightmost LED, and the end on the left side of the emission surface 22s of the second light source 22 is the end on the left side of the emission surface of the leftmost LED. It should be noted that the connection portion 35e1c may also be located inside the two ends of the emission surface 22s of the second light source 22 in the left-right direction.

[0049] In addition, the edge 35e2 of each cutout 35 on the side opposite to the center side of the second opening 32h is connected to the end of the edge of the second opening 32h in the left-right direction. Moreover, the cutout 35 on the right side extends along the left side 32rs of the second right side reflection part 32r, and the cutout 35 on the left side extends along the right side 32ls of the second left side reflection part 32l. Therefore, the edge 35e2 of the cutout 35 on the right side is the left side 32rs of the second right side reflection part 32r, and the edge 35e2 of the cutout 35 on the left side is the right side 32ls of the second left side reflection part 32l. Moreover, the edge 35e2 of the edge of the second opening 32h from the end on the right side to the edge of the cutout 35 on the right side is formed by a curved surface with a substantially constant curvature, and the edge 35e2 of the edge of the second opening 32h from the end on the left side to the edge of the cutout 35 on the left side is formed by a curved surface with a substantially constant curvature. It should be noted that the edge 35e2 of each cutout 35 may also be connected to a portion of the edge of the second opening 32h that is closer to the inside than the end in the left-right direction. In addition, the cutout 35 on the right side may not be along the left side surface 32rs of the second right side reflecting portion 32r, and the cutout 35 on the left side may not be along the right side surface 32ls of the second left side reflecting portion 32l. For example, a portion of the second lower side reflecting portion 32d may be located between the cutout 35 on the right side and the second right side reflecting portion 32r, and another portion of the second lower side reflecting portion 32d may be located between the cutout 35 on the left side and the second left side reflecting portion 32l.

[0050] In addition, the front end portion, i.e., the lower end portion, of each cutout 35 in the extending direction is bent in a manner close to the center side of the second opening 32h in the left-right direction, but it does not need to be bent in this manner. For example, it may be bent in a manner away from the center side of the second opening 32h.

[0051] The projection lens 40 is a lens that changes the divergence angle of the transmitted light. Figure 3 As shown, it is arranged in front of the reflector unit 30. In the present embodiment, the projection lens 40 is a biconvex aspheric lens having a substantially circular outer shape, and a flange portion 41 protruding outward and extending over the entire circumference is provided on the outer peripheral surface of the projection lens 40. The optical axis of the projection lens 40 extends in the front-to-back direction, intersects with the beam shaper BS, and passes between the first opening 31h and the second opening 32h. In addition, the focus of the rear side of the projection lens 40 is located near the front end BSe between the front end BSe of the beam shaper BS and the projection lens 40, and the vicinity of the front end BSe is, for example, a position at a distance of 10 mm or less from the front end BSe. It should be noted that the focus of the rear side of the projection lens 40 may be located at the front end BSe, or may overlap with the beam shaper BS. As materials constituting the projection lens 40, for example, resin, glass, etc. may be cited.

[0052] The holder 50 supports the projection lens 40 and is fixed to the heat sink 10. In the present embodiment, the holder 50 has a cylindrical support portion 51 extending in the front-to-back direction, and a pair of legs 52 extending rearward from the left and right sides of the rear end of the support portion 51. A plurality of pedestals 53 protruding forward are provided at the front end of the support portion 51, and the flange portion 41 of the projection lens 40 is fixed to the pedestals 53, for example, by ultrasonic welding or laser welding. The legs 52 are fixed to the heat sink 10 by screws 83, and the projection lens 40 is fixed to the heat sink 10 via the holder 50. As a material constituting the holder 50, for example, an opaque resin such as polycarbonate can be cited, and in the present embodiment, the support portion 51 and the legs 52 are formed integrally. It should be noted that the structure of the holder 50 is not limited.

[0053] The light shielding plate 60 is a light-impermeable plate-shaped member disposed between the projection lens 40 and the substrate 20 below the reflecting portion 30a of the reflector unit 30. In the present embodiment, the light shielding plate 60 is fixed to the holder 50 by screws 84. Figure 8 is a vertical cross-sectional view of the lamp unit 2. It should be noted that, Figure 8 is a vertical cross-sectional view along the optical axis 40c of the projection lens 40. Figure 8 In the embodiment, the heat sink 10 is omitted. Figure 8 As shown, the shading plate 60 is arranged between the projection lens 40 and the connector 23 mounted on the substrate 20. In addition, the shading plate 60 covers the lower side of the inner peripheral surface of the support portion 51 of the holder 50. Therefore, the shading plate 60 protects the connector 23 and the support portion 51 from the sunlight incident from the projection lens 40. As a member constituting the shading plate 60, for example, a metal plate can be cited. It should be noted that the structure of the shading plate 60 is not limited.

[0054] Next, formation of the low-beam light distribution pattern of the vehicle headlamp 1 will be described.

[0055] When forming a low-beam light distribution pattern, light is emitted from the first light source 21. Figure 7As shown, among the light emitted from the emission surface 21s of the first light source 21, the light emitted in a direction substantially parallel to the perpendicular line of the emission surface 21s is not reflected by the first reflection portion 31 but directly enters the projection lens 40. In addition, the light emitted to the upper front side with reference to the perpendicular line of the emission surface 21s is reflected forward at the lower surface 31us of the first upper reflection portion 31u, and the light emitted to the lower front side is reflected forward at the upper surface 31ds of the first lower reflection portion 31d. Although the illustration is omitted, the light emitted to the right front side is reflected forward at the left side surface 31rs of the first right side reflection portion 31r, and the light emitted to the left front side is reflected forward at the right side surface 31ls of the first left side reflection portion 31l. In this way, the light reflected by the first reflection portion 31 enters the projection lens 40. As described above, the front end BSe of the beam shaper BS, which is composed of the first lower reflector 31d of the first reflector 31 and the second upper reflector 32u of the second reflector 32, has a shape that matches the cut-off line, so the cut-off line in the low-beam light distribution pattern is formed by light passing through the vicinity of the front end BSe of the beam shaper BS. In addition, the protrusion 31db provided on the upper surface 31ds of the first lower reflector 31d, which is the upper surface of the beam shaper BS, reflects and shields a part of the light emitted from the emission surface 21s so as not to enter the projection lens 40. Therefore, a predetermined area in the low-beam light distribution pattern can be darkened. In this way, the low-beam light distribution pattern is formed by the light emitted from the emission surface 21s and directly entering the projection lens 40 and the light emitted from the emission surface 21s and reflected by the first reflector 31 and entering the projection lens 40. The light having the low-beam light distribution pattern passes through the projection lens 40 and is emitted from the vehicle headlamp 1 via the front cover 3c. As described above, the rear focus of the projection lens 40 is located near the front end BSe, and therefore the light distribution pattern of the low beam projected toward the front of the vehicle is a light distribution pattern inverted by the projection lens 40 .

[0056] Fig. 9 is a diagram showing a low beam distribution pattern in this embodiment. Fig. 9In FIG. 1 , S represents a horizontal line, V represents a vertical line passing through the center of the vehicle in the left-right direction, and the low-beam light distribution pattern PL projected on an imaginary vertical screen disposed 25 m in front of the vehicle is represented by a bold line. The low-beam light distribution pattern PL of the present embodiment is a light distribution pattern in a country or region where vehicles pass on the right side. The first reflecting portion 31 is formed so that the light distribution pattern of the light from the exit surface 21s incident on the projection lens 40 becomes the shape of such a low-beam light distribution pattern PL. The cut-off line CL of the low-beam light distribution pattern PL corresponds to the shape of the front end BSe of the beam shaper BS, and has a step CLs in the present embodiment. In addition, most of the light reflected on the lower surface 31us of the first upper side reflecting portion 31u is irradiated to the lower side of the low-beam light distribution pattern PL, and most of the light reflected on the upper surface 31ds of the first lower side reflecting portion 31d is irradiated to the upper side of the low-beam light distribution pattern PL. In addition, most of the light reflected by the left side surface 31rs of the first right side reflector 31r is irradiated to the left side of the low-beam light distribution pattern PL, and most of the light reflected by the right side surface 31ls of the first left side reflector 31l is irradiated to the right side of the low-beam light distribution pattern PL. In addition, the area AR1 in the low-beam light distribution pattern PL is darker than other areas, and the area AR1 is located closer to the opposite lane OL than the step CLs.

[0057] Next, formation of the high-beam light distribution pattern of the vehicle headlamp 1 will be described.

[0058] When forming a high-beam light distribution pattern, light is emitted from the first light source 21 and the second light source 22. Therefore, as described above, the low-beam light distribution pattern PL is formed by the light from the first light source 21, and the light having the low-beam light distribution pattern PL is emitted from the vehicle headlamp 1. Figure 7As shown, among the light emitted from the emission surface 22s of the second light source 22, the light emitted in a direction substantially parallel to the perpendicular line of the emission surface 22s is not reflected by the second reflection portion 32 but directly enters the projection lens 40. In addition, the light emitted to the upper side in the front with the perpendicular line of the emission surface 22s as a reference is reflected forward at the lower surface 32us of the second upper reflection portion 32u, and the light emitted to the lower side in the front is reflected forward at the upper surface 32ds of the second lower reflection portion 32d. Although the illustration is omitted, the light emitted to the right side in the front is reflected forward at the left side surface 32rs of the second right side reflection portion 32r, and the light emitted to the left side in the front is reflected forward at the right side surface 32ls of the second left side reflection portion 32l. As described above, the second lower reflection portion 32d is provided with a cutout 35, which extends downward from the left and right sides of the upper surface 32ds, which is the lower edge of the second opening 32h. Therefore, the light reflected forward by the left side surface 32rs of the second right side reflection part 32r includes the light passing through the second opening 32h and the light passing through the right side cutout 35, and the light reflected forward by the right side surface 32ls of the second left side reflection part 32l includes the light passing through the second opening 32h and the light passing through the left side cutout 35. In addition, by using the light passing through the vicinity of the front end BSe of the beam shaper BS, a cut-off line corresponding to the front end BSe is formed on the light distribution pattern formed by the light emitted from the emission surface 22s. In this way, an additional light distribution pattern is formed by the light emitted from the emission surface 22s and directly entering the projection lens 40 and the light emitted from the emission surface 22s and reflected by the second reflection part 32 and entering the projection lens 40. The additional light distribution pattern is a light distribution pattern that forms a high-beam light distribution pattern by adding to the low-beam light distribution pattern PL. The light having the additional light distribution pattern passes through the projection lens 40 and is emitted from the vehicle headlamp 1 via the front cover 3c. Therefore, light having a high-beam light distribution pattern is emitted from the vehicle headlamp 1. It should be noted that the additional light distribution pattern projected to the front of the vehicle is the same as the low-beam light distribution pattern PL, and is a light distribution pattern inverted by the projection lens 40. In addition, the cut-off line of the additional light distribution pattern is the same as the cut-off line CL of the low-beam light distribution pattern PL, and is defined by the front end BSe of the beam shaper BS. Therefore, the cut-off line of the additional light distribution pattern is substantially consistent with the cut-off line CL of the low-beam light distribution pattern PL, and the high-beam light distribution pattern becomes a light distribution pattern in which the additional light distribution pattern and the low-beam light distribution pattern PL are connected.

[0059] In the present embodiment, the upper side of the low beam distribution pattern PL overlaps with the lower side of the additional light distribution pattern, but the low beam distribution pattern PL and the additional light distribution pattern may not overlap. In this case, at least a portion of the cut-off line of the additional light distribution pattern coincides with at least a portion of the cut-off line CL of the low beam distribution pattern PL, and the additional light distribution pattern is connected to the low beam distribution pattern PL.

[0060] Fig.10is a diagram showing a high beam distribution pattern in this embodiment, and is Fig. 9 The figure similarly shows the high beam distribution pattern. Fig.10 In the figure, the cut-off line CL in the low-beam light distribution pattern PL is indicated by a dotted line. The area LAR below the cut-off line CL in the high-beam light distribution pattern PH is mainly formed by the light from the first light source 21, and the area HAR above the cut-off line CL is mainly formed by the light from the second light source 22. In addition, most of the light reflected by the lower surface 32us of the second upper side reflector 32u of the second reflector 32 is irradiated to the lower side of the area HAR above the cut-off line CL, and most of the light reflected by the upper surface 32ds of the second lower side reflector 32d is irradiated to the upper side of the area HAR. In addition, most of the light reflected by the left side surface 32rs of the second right side reflector 32r is irradiated to the left side of the area HAR, and most of the light reflected by the right side surface 32ls of the second left side reflector 32l is irradiated to the right side of the area HAR.

[0061] As described above, the vehicle headlamp 1 of the present embodiment includes the second light source 22 having the light emitting surface 22s directed to the front side, and the reflector unit 30. The reflector unit 30 includes: a second opening 32h through which the emitting surface 22s of the second light source 22 is exposed; a second reflecting portion 32 disposed at a position closer to the front side than the emitting surface 22s and surrounding the second opening 32h. The second reflecting portion 32 includes: a second upper reflecting portion 32u that reflects the light emitted from the emitting surface 22s forward and extends upward from the upper edge of the second opening 32h; a second lower reflecting portion 32d that extends downward from the lower edge of the second opening 32h; a second left reflecting portion 32l that extends from the left edge of the second opening 32h to the left side; and a second right reflecting portion 32r that extends from the right edge of the second opening 32h to the right side. The second lower reflector 32d of the second reflector 32 is provided with a cutout 35, which extends downward from the left and right sides of the upper surface 32ds, which is the lower edge of the second opening 32h, respectively, and allows a part of the light emitted from the emission surface 22s to pass through. Therefore, according to the vehicle headlamp 1 of this embodiment, the light passing through the cutout 35 on the left side can be incident on the second reflector 32, which is a portion on the left side of the second opening 32h, that is, a position on the lower side of the second opening 32h in the second left reflector 32l. In addition, according to the vehicle headlamp 1 of this embodiment, the light passing through the cutout 35 on the right side can be incident on the second reflector 32, which is a portion on the right side of the second opening 32h, that is, a position on the lower side of the second opening 32h in the second right reflector 32r. Therefore, according to the vehicle headlamp 1 of the present embodiment, it is possible to suppress the difficulty of light from the second light source 22 to enter the lower side of the second opening 32h in the second left reflection portion 32l and the second right reflection portion 32r, compared with the case where the above-mentioned cutout 35 is not provided. Therefore, according to the vehicle headlamp 1 of the present embodiment, it is possible to suppress the formation of dark areas on the left and right sides of the light distribution pattern of the emitted light, compared with the above-mentioned case. Specifically, it is possible to suppress Fig.10 In the illustrated high-beam light distribution pattern PH, dark areas are formed on the left and right sides of a region HAR above the cut-off line CL.

[0062] In the vehicle headlamp 1 of the present embodiment, the connection portion 35e1c between the edge of the center side of the second opening 32h of each cutout 35 and the edge of the second opening 32h is located outside the two ends of the emission surface 22s in the left-right direction. Therefore, according to the vehicle headlamp 1 of the present embodiment, compared with the case where the connection portion 35e1c is located inside the two ends of the emission surface 22s in the left-right direction, it is possible to suppress the left and right sides of the light distribution pattern of the light reflected by the second lower side reflection portion 32d on the upper and lower sides of the second opening 32h where the cutout 35 is provided from becoming darker or the width of the light distribution pattern in the left-right direction from becoming narrower. Therefore, according to the vehicle headlamp 1 of the present embodiment, compared with the above-mentioned case, it is possible to suppress the left and right sides of the light distribution pattern of the light reflected by the second lower side reflection portion 32d on the upper and lower sides of the second opening 32h from becoming darker or the width of the light distribution pattern in the left-right direction from becoming narrower. Fig.10 The left and right sides of the region HAR of the high-beam distribution pattern PH shown in the figure form dark regions.

[0063] As mentioned above, although the present invention has been described by taking the above-mentioned embodiment as an example, the present invention is not limited thereto.

[0064] For example, in the above embodiment, the lamp unit 2 is described as an example in which a lamp unit emitting light having a low-beam distribution pattern and a lamp unit emitting light having an additional distribution pattern are integrated. However, the vehicle headlamp may also be a structure in which a lamp unit emitting light having a low-beam distribution pattern and a lamp unit emitting light having an additional distribution pattern are separately constituted and provided with these lamp units. In addition, the distribution pattern of the light emitted by the lamp unit is not particularly limited.

[0065] In addition, in the above-mentioned embodiment, the reflector unit 30 having the second reflector 32 is described as an example, and the second reflector 32 includes a second upper reflector 32u, a second lower reflector 32d, a second left reflector 32l and a second right reflector 32r, and a cutout 35 is provided in the second lower reflector 32d. However, the reflector unit 30 only needs to have an opening for exposing the light exit surface of the light source, and a reflector arranged on the front side of the exit surface and surrounding the opening. In addition, the reflector may be provided with a cutout, which extends from the left and right sides of at least one of the upper edge and the lower edge of the opening in the upward and downward directions, respectively, for a part of the light emitted from the exit surface to pass through. According to such a structure, the light passing through the cutout on the left side can be incident on the portion of the reflector on the left side of the opening, and the light passing through the cutout on the right side can be incident on the portion of the reflector on the right side of the opening. The left and right cutouts extend in the up-down direction from at least one of the upper and lower edges of the opening, so the part where the light passing through the cutout is incident is located on the side of the cutout based on the opening in the up-down direction, and is located at least one side of the upper and lower sides of the opening. Therefore, according to such a structure, compared with the case where the above-mentioned cutout is not provided, it is possible to suppress the light from the light source from being difficult to be incident on the part of the reflector that is closer to the outside than the opening in the left-right direction and closer to the lower side or the upper side than the opening, and it is possible to suppress the formation of dark areas on the left and right sides of the light distribution pattern of the emitted light. For example, in the second reflector 32 of the above-mentioned embodiment, the second upper reflector 32u, the second lower reflector 32d, the second left reflector 32l and the second right reflector 32r can also be connected in an integral manner without dividing the boundaries with each other. In addition, a cutout can also be provided in the first upper reflector 31u of the first reflector 31 of the above-mentioned embodiment, and the cutout extends upward from the upper edge of the first opening 31h, that is, the left and right sides of the lower surface 31us, respectively, for a part of the light emitted from the exit surface 21s of the first light source 21 to pass. In addition, when the lamp unit that emits light with a low-beam distribution pattern and the lamp unit that emits light with an additional distribution pattern are constructed separately, cutouts can be provided on the left and right sides of both the upper and lower edges of the opening exposed from the exit surface of the light source, respectively extending in the upward and downward directions and allowing a portion of the light emitted from the exit surface to pass through.

[0066] According to the present invention, a vehicle headlamp capable of suppressing formation of dark areas on both left and right sides of a light distribution pattern is provided, and the vehicle headlamp can be used in the field of vehicle headlamps such as automobiles.

Claims

1. A vehicle headlamp, characterized in that: have: a light source having a light emitting surface facing the front side; a reflector unit having an opening through which the emission surface is exposed, and a reflecting portion disposed on the front side of the emission surface and surrounding the opening, The reflecting portion reflects the light emitted from the emitting surface forward. The reflecting portion is provided with a cutout extending in the up-down direction from both left and right sides of at least one of the upper edge and the lower edge of the opening, respectively, and allowing a part of the light emitted from the emission surface to pass through the cutout.

2. The vehicle headlamp according to claim 1, characterized in that: A connection portion between an edge on a center side of the opening of each of the cutouts and an edge of the opening is located outside of both ends of the emission surface in the left-right direction.

3. The vehicle headlamp according to claim 1, characterized in that: The edge of each of the cutouts on the opposite side to the center side of the opening is connected to the end of the edge of the opening in the left-right direction.

4. The vehicle headlamp according to claim 1, characterized in that: The front end portion of each of the cutouts is bent so as to approach the center side of the opening in the left-right direction.

5. The vehicle headlamp according to any one of claims 1 to 4, characterized in that: Also available: a heat sink having a mounting surface for mounting the substrate on which the light source is mounted; and a bracket abutting against the heat sink from the rear side at a position below the mounting surface to fix the heat sink. The heat sink is provided with a screw through hole that penetrates in the front-rear direction and through which a screw that fixes the heat sink to the bracket is inserted. A contact surface of the heat sink on which the screw contacts is located rearward of a plane overlapping the mounting surface.

6. The vehicle headlamp according to claim 5, characterized in that: The heat sink is provided with a pin through-hole into which a pin provided on the bracket is inserted at a position below the screw through-hole.

7. The vehicle headlamp according to claim 6, characterized in that: The heat sink has a bottom plate including the mounting surface on a main surface on the front side. The upper edge of the bottom plate has inclined portions at both ends in the left-right direction, which are inclined linearly downward toward the outer sides in the left-right direction.

Images