A headlight assembly

Abstract

The present invention provides a headlamp assembly, comprising a light source and a light guide structure, wherein the light guide structure comprises a focusing surface, a plurality of reflecting surfaces, a multi-elliptical reflecting surface, a cut-off line forming surface and a lens surface, wherein the focusing surface is used to focus the light emitted by the light source and form collimated light, wherein the plurality of reflecting surfaces are used to reflect part of the collimated light and finally reflect the part of the light to the multi-elliptical reflecting surface, wherein the multi-elliptical reflecting surface is used to receive the part of the light and reflect the part of the light to the lens surface, wherein the cut-off line forming surface has a light-shielding upper surface and an end portion, wherein the upper surface forms a stepped surface in the transverse direction of the light guide structure, wherein the end portion is arranged on the side of the stepped surface close to the lens surface, and wherein the lens surface is used to project illumination light including the part of the light reflected by the multi-elliptical reflecting surface and the rest of the light in the collimated light. The present invention solves the problem of assembly difficulty caused by the complex structure of the parts of the headlamp assembly.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile lighting, and in particular to a headlamp assembly. Background Art

[0002] In the field of automotive lighting technology, low beam is an essential lighting device for vehicles driving at night or in low visibility conditions. Its performance is directly related to driving safety and driving comfort. In order to meet the requirements of vehicle low beam regulations in various countries, the industry has continuously explored and adopted a variety of optical design solutions to achieve efficient low beam function modules.

[0003] At present, the mainstream optical solutions mainly include four types: the first solution combines the light source, reflective bowl, shading sheet and aspherical lens, and forms a low beam light type that complies with regulations through the reflection effect of the reflective bowl and the shading effect of the shading sheet, in cooperation with the projection of the aspherical lens; the second solution adopts a combination of light source, condenser lens, shading sheet and aspherical lens. The condenser lens is used to enhance the concentration of the light source and redistribute the light, which is then projected through the shading sheet and aspherical lens to meet the low beam standard; the third solution uses a light source, a total reflection lens and an aspherical lens. The total reflection lens can only realize light path control, but cannot effectively control the distribution of light; the fourth solution is a combination of light source, reflective bowl (the cut-off line shape is designed at the rear edge of the reflective bowl) and aspherical lens. The desired low beam effect is formed through the initial reflection of the reflective bowl and further adjustment of the aspherical lens.

[0004] However, these solutions all have many parts, complex structures, and diverse materials, which will lead to many assembly difficulties. Multiple parts need to be precisely assembled, which not only increases the difficulty of processing and procurement, but also prolongs the production cycle and cost; at the same time, as the number of parts increases, the assembly accuracy of the module assembly also faces challenges. Any slight assembly error may affect the accuracy and regulatory compliance of the low beam pattern. Therefore, there is an urgent need for a low beam function module design that simplifies the structure, improves assembly accuracy, and reduces costs. Summary of the invention

[0005] The purpose of the present invention is to provide a headlamp assembly to solve the problems in the prior art that the parts of the headlamp assembly are complex in structure, made of various materials, difficult to integrate in design, and lead to assembly difficulties.

[0006] In order to achieve the above-mentioned object of the present invention, an embodiment of the present invention provides a headlamp assembly, which includes:

[0007] a light source for emitting light; and

[0008] Light guide structure,

[0009] The light guide structure comprises:

[0010] A focusing surface, the focusing surface is used to focus the light emitted by the light source and form collimated light;

[0011] A plurality of reflecting surfaces, used for reflecting part of the collimated light and reflecting the part of the light to a plurality of elliptical reflecting surfaces;

[0012] A multi-elliptical reflective surface, used for receiving the part of light and reflecting the part of light to the lens surface;

[0013] A cut-off line forming surface, comprising an upper surface and an end portion, wherein the upper surface forms a step surface in the lateral direction of the light guide structure, and the end portion is disposed on a side of the step surface close to the lens surface;

[0014] A lens surface, wherein the lens surface is used to project illumination light including the portion of light reflected by the multi-elliptical reflection surface and the remaining light in the collimated light, wherein the light distribution pattern formed after the illumination light is projected includes a light-dark cutoff line corresponding to the end shape, and the portion of light forms a brightening portion below the light-dark cutoff line after being projected through the lens surface.

[0015] As a further improvement of an embodiment of the present invention, the light-guiding structure is an optical element of an integrated structure formed by transparent materials.

[0016] As a further improvement of an embodiment of the present invention, the shape of the cut-off line is a shape corresponding to the shape of the edge portion connecting the end portion and the upper surface.

[0017] As a further improvement of an embodiment of the present invention, the lens surface has an optical axis formed in the horizontal direction, the light guide structure has a mounting end arranged relative to the lens surface, and a mounting groove is arranged on the mounting end, the mounting groove penetrates the light guide structure in the lateral direction of the light guide structure and has a first side wall and a second side wall located on the upper and lower sides of the optical axis, the bottom of the mounting groove is arranged to be an arc-shaped surface protruding in the direction away from the lens surface, the focusing surface includes two focusing side walls arranged opposite to each other in the vertical direction, the first side wall, the second side wall and the arc-shaped surface, the focusing side wall extends from the mounting end toward the lens surface and away from the optical axis, the first side wall and the second side wall are located between the two focusing side walls, and the light source is arranged in the mounting groove and emits the light to the first side wall, the second side wall and the arc-shaped surface.

[0018] As a further improvement of one embodiment of the present invention, the multiple reflecting surfaces include a first reflecting surface and a second reflecting surface arranged opposite to each other in the vertical direction, the light from the light source is incident from the first side wall and converged into a first collimated light through a focusing side wall, the light from the light source is incident from the curved surface and converged into a second collimated light, the first collimated light and the second collimated light pass between the first reflecting surface and the second reflecting surface and are projected onto the lens surface, the light from the light source is incident from the second side wall and converged into a third collimated light through another focusing side wall and then projected onto the first reflecting surface, then reflected from the first reflecting surface to the second reflecting surface, and finally reflected from the second reflecting surface to the multi-elliptical reflecting surface.

[0019] As a further improvement of one embodiment of the present invention, in the direction parallel to the optical axis, the first reflecting surface is arranged relative to the other focusing side wall, the first reflecting surface has a first end and a second end arranged opposite to each other, the first end intersects with the optical axis, and the first reflecting surface extends from the first end along the direction away from the lens surface and away from the optical axis to the second end.

[0020] As a further improvement of an embodiment of the present invention, the angles between the first reflecting surface and the second reflecting surface and the optical axis are between 42.5° and 50°.

[0021] As a further improvement of an embodiment of the present invention, the light-guiding structure further includes a light-shielding surface, one end of the light-shielding surface is connected to the end portion, and the other end of the light-shielding surface extends toward the lens surface and away from the optical axis.

[0022] As a further improvement of an embodiment of the present invention, the upper surface has a first step surface located on the left side of the light guide structure in the horizontal direction and a second step surface located on the right side, the first step surface and the second step surface are both parallel to the optical axis, the angle between the shading surface and the first step surface is a, in the direction parallel to the optical axis, the distance from the lens surface to the lower end of the multi-elliptical reflection surface is L, in the direction perpendicular to the optical axis, the distance from the lower end of the lens surface to the lower end of the second reflection surface is K, and the angle a≤actan(K / L).

[0023] As a further improvement of an embodiment of the present invention, the first step surface is lower than the second step surface, and the distances from the optical axis to the first step surface and the second step surface are both no greater than 0.6 mm.

[0024] As a further improvement of an embodiment of the present invention, all the focal points of the multi-elliptical reflection surface are located in the focal plane of the lens surface.

[0025] As a further improvement of an embodiment of the present invention, the poly-elliptical reflective surface includes a poly-elliptical reflective surface body formed by a portion on the side wall of the light guide structure and a reflective film coated on the outside of the poly-elliptical reflective surface body.

[0026] As a further improvement of an embodiment of the present invention, the distance between the focus of the lens surface and the end is not greater than 0.5 mm.

[0027] Compared with the prior art, the present invention has the following beneficial effects:

[0028] The integrated light-guiding structure is adopted to effectively avoid the assembly difficulties and insufficient precision problems caused by the complex parts structure and wide variety of materials of the headlight assembly, and solves the problem that the existing designs in the industry are difficult to design into an integrated structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 A schematic structural diagram of a headlamp assembly provided by one embodiment of the present invention;

[0030] Figure 2 for Figure 1 Bottom view of

[0031] Figure 3 for Figure 1 The main view of

[0032] Figure 4 for Figure 1 The enlarged view of the M in the middle;

[0033] Figure 5 for Figure 1 Left view of

[0034] Figure 6 for Figure 1 Right view of;

[0035] Figure 7 for Figure 2 Schematic diagram of the cross section in the BB direction;

[0036] Figure 8 for Figure 2 Schematic diagram of the cross section in the AA direction;

[0037] Fig. 9 for Figure 7 Schematic diagram after removing light;

[0038] Fig.10 The contour line display shows Figure 1 A diagram of the illuminance distribution of the illumination light projected by a headlamp assembly.

[0039] The above description of the drawings includes the following reference numerals:

[0040] 1. Light source;

[0041] 2. Light guide structure;

[0042] 21. Focusing surface;

[0043] 211, focusing side wall;

[0044] 22. Multi-elliptical reflective surface;

[0045] 23. The cut-off line forms a surface;

[0046] 230, upper surface;

[0047] 231. End;

[0048] 232, first step surface;

[0049] 233, second step surface;

[0050] 234, connection surface;

[0051] 24. Lens surface;

[0052] 241, optical axis;

[0053] 25. Installation end;

[0054] 251, mounting slot;

[0055] 2511, first side wall;

[0056] 2512, second side wall;

[0057] 2513, curved surface;

[0058] 26. A first reflecting surface;

[0059] 261, first end;

[0060] 262, second end;

[0061] 27. A second reflecting surface;

[0062] 28. Light-shielding surface;

[0063] 3. Brightness and darkness cut-off line;

[0064] 31. First horizontal section;

[0065] 32. Second horizontal section;

[0066] 33. Connecting section. DETAILED DESCRIPTION

[0067] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0068] It should be noted that, unless otherwise specified, all technical and scientific terms used in this application have the same meanings as commonly understood by ordinary technicians in the technical field to which this application belongs.

[0069] In the present invention, unless otherwise specified, the directional words used, such as "up, down, top, bottom", usually refer to the directions shown in the drawings, or to the components themselves in the vertical, perpendicular or gravity directions; similarly, for ease of understanding and description, "inside and outside" refer to the inside and outside relative to the outline of each component itself, but the above-mentioned directional words are not used to limit the present invention.

[0070] In order to solve the problem of difficult assembly caused by complex parts structure and various materials of the headlight assembly in the prior art, the present invention provides a headlight assembly.

[0071] Hereinafter, a headlamp assembly in an embodiment of the present invention will be described with reference to the accompanying drawings. In each figure, the same or similar structures are denoted by the same reference numerals. The following embodiments are merely examples, and various modifications can be made within the scope of the present invention.

[0072] In the figure, in order to facilitate the understanding of the present invention, the coordinate axes of the XYZ rectangular coordinate system are shown. The X-axis is a coordinate axis extending in the left-right direction (that is, in the lateral direction) of the vehicle equipped with the headlamp assembly. When facing the front of the vehicle, the right side is the +X-axis direction, and the left side is the -X-axis direction. "Front" is the direction of travel when the vehicle is moving straight ahead. That is, "front" is the direction in which the headlamp assembly irradiates light. The Y-axis is a coordinate axis extending in the up-down direction (that is, in the vertical direction) of the vehicle. The upper side is the +Y-axis direction, and the lower side is the -Y-axis direction. The "upper side" is the direction toward the sky, and the "lower side" is the direction toward the ground (such as the road surface, etc.). The Z-axis is a coordinate axis extending in the direction of travel when the vehicle is moving straight ahead. The direction of travel when the vehicle is moving straight ahead is the +Z-axis direction, and the direction of travel when the vehicle is moving straight behind is the -Z-axis direction. The +Z-axis direction is also called "front", and the -Z-axis direction is also called "back".

[0073] The ZX plane is a plane parallel to the road surface. However, the road surface is inclined in uphill, downhill, or width-inclined roads. Therefore, the plane perpendicular to the gravity direction, i.e., the horizontal plane, is sometimes not actually parallel to the road surface. However, in this application, the plane parallel to the road surface, i.e., the ZX plane, is also referred to as a "horizontal plane".

[0074] The headlamp assembly, for example, illuminates the front of the vehicle. The headlamp assembly must be able to illuminate light of a light distribution pattern that illuminates an area specified by laws, etc. (hereinafter referred to as "road traffic regulations"). "Light distribution" refers to the luminance of a lighting device in each direction, that is, the luminance distribution. In other words, "light distribution" is the spatial intensity distribution of light emitted from a lighting device. In addition, "luminance" is a physical quantity that indicates how strong the light emitted from a light source is. Luminance is a value obtained by dividing a light beam passing through a small solid angle in a certain direction by the small solid angle.

[0075] Generally speaking, road traffic regulations require that the low beam light distribution pattern of a headlamp device for a car be a horizontally long shape that is shorter in the vertical direction and longer in the left-right direction. In addition, in order not to dazzle the driver of the oncoming car, road traffic regulations require that the boundary line of light on the upper side of the light distribution pattern (i.e., the light cutoff line) be clear. "Clear" means that the light cutoff line does not produce a large color difference or a large blur, etc. That is, road traffic regulations require that the area on the upper side of the light cutoff line (i.e., the outer side of the light distribution pattern) is dark enough, the area on the lower side of the light cutoff line (i.e., the inner side of the light distribution pattern) is bright enough, and the light cutoff line is clear enough.

[0076] Here, the "cutoff line" is a dividing line between a brighter area and a darker area formed when the light emitted from the headlamp assembly is irradiated onto a wall or a screen. Generally speaking, the cutoff line is a dividing line existing on the upper side of the light distribution pattern. That is, the cutoff line refers to the boundary line between the light and dark of the light on the upper side of the light distribution pattern. That is, the cutoff line is the boundary line between the brighter area (i.e., the area on the inner side of the light distribution pattern) and the darker area (i.e., the area on the outer side of the light distribution pattern) on the upper side of the light distribution pattern. The cutoff line is a term used to explain the irradiation direction of the headlamp used when cars pass each other. The light distribution pattern of the headlamp used when cars pass each other is also called low beam.

[0077] The “light distribution pattern” refers to the shape of a light beam and the intensity distribution of light determined by the direction of light emitted from a light source.

[0078] “Light distribution pattern” is also used to mean the illumination pattern on the illuminated surface. “Light distribution” means the distribution of the intensity of light emitted from a light source with respect to the direction of the light. “Light distribution” is also used to mean the illumination distribution on the illuminated surface.

[0079] The headlamp assembly according to the embodiment is used for irradiation of a low beam or a high beam of a headlamp mounted on a vehicle.

[0080] For example, the headlamp assembly is used as a headlamp for a motorcycle. In addition, the headlamp assembly is also used as a headlamp for various vehicles such as three-wheeled or four-wheeled vehicles. For example, a three-wheeled vehicle includes an automatic tricycle called a gyro. An automatic tricycle is a scooter consisting of three wheels, with a front wheel as one wheel and a rear wheel as one axle and two wheels.

[0081] In the following description, the case of forming a light distribution pattern of a low beam of a headlamp assembly for a family car is mainly described. The light distribution pattern of a low beam of a headlamp assembly for a family car includes a cut-off line, and the cut-off line includes a horizontal straight line in the left-right direction of the vehicle (i.e., the X-axis direction). In addition, the area below the cut-off line (i.e., the inner side of the light distribution pattern) is the brightest. Example

[0082] like Figure 1-10 , generally shows a headlamp assembly provided by the present embodiment, and the headlamp assembly specifically includes a light source 1 and a light guide structure 2.

[0083] The light source 1 is used to emit light, and the light guide structure 2 includes a light focusing surface 21 , a plurality of reflection surfaces, a multi-elliptical reflection surface 22 , a cut-off line forming surface 23 and a lens surface 24 .

[0084] The focusing surface 21 is used to converge the light emitted by the light source 1 and form collimated light. “Collimated light” refers to light that becomes substantially parallel after being converged. In the present embodiment, the collimated light is substantially parallel to the optical axis 241 .

[0085] The multiple reflection surfaces are used to reflect part of the collimated light and reflect the part of the light to the multi-elliptical reflection surface 22 . The multi-elliptical reflection surface 22 is used to receive the part of the light and reflect the part of the light to the lens surface 24 .

[0086] The cut-off line forming surface 23 has a light-shielding upper surface 230 and an end portion 231. The upper surface 230 is in the horizontal direction of the light guide structure 2 (refer to Figure 8 As shown, that is, in the direction of the X-axis), a stepped surface is formed, and the end portion 231 is arranged on a side of the stepped surface close to the lens surface 24.

[0087] In this embodiment, the upper surface 230 can be configured as a light-absorbing surface. The “light-absorbing surface” means that most of the light incident on the surface is absorbed and is neither refracted nor reflected, thereby achieving a light-shielding effect.

[0088] Of course, in some embodiments, the upper surface 230 may also be a transparent surface, and such a configuration does not affect the formation of the cut-off line 3 .

[0089] The lens surface 24 is used to project illumination light including the portion of light reflected by the multi-elliptical reflection surface 22 and the remaining light in the collimated light, wherein the light distribution pattern formed after the illumination light is projected includes a light-dark cutoff line 3 corresponding to the shape of the end 231, and the portion of light forms a brightening portion below the light-dark cutoff line 3 after being projected through the lens surface 24.

[0090] <Light Source 1>

[0091] The light source 1 is equipped with a light-emitting surface that can emit light. From the perspective of reducing carbon dioxide (CO2) emissions and saving fuel consumption, thereby reducing the burden on the environment, it is recommended to select a semiconductor with high luminous efficiency as the light source 1. Examples of semiconductor light sources include light-emitting diodes (LEDs) and laser diodes (LDs). In addition, the light source 1 can also use traditional lamps such as halogen lamps as light sources. In addition, the light source 1 can also be a solid-state light source, such as organic electroluminescence (organic EL) or a type that makes a fluorescent body emit light by irradiating excitation light. It is worth noting that semiconductor light sources are a type of solid-state light source.

[0092] <The Movement of Light>

[0093] refer to Figure 7 As shown, after the light source 1 emits light, the light is emitted from the -Z axis side toward the Z axis side, the lens surface 24 is located on the +Z axis side of the light guide structure 2, and the light emitted by the light source is converged by the focusing surface 21 to form collimated light. Some of the collimated light is reflected by the multiple reflection surfaces, and finally the part of the light is reflected to the multi-elliptical reflection surface 22, the multi-elliptical reflection surface 22 receives the part of the light and reflects the part of the light to the lens surface 24, the "multi-elliptical reflection surface" is an end in the major axis direction of the ellipse (the end of the ellipse located on the -Z axis side in the present invention), and extends in a direction intersecting with the optical axis 241 to form an arc-shaped surface.

[0094] It should be noted that the multi-elliptical reflective surface 22 has a converging effect on light and has many focal points. The part of light reflected by the multi-elliptical reflective surface 22 forms the first illumination light projected onto the lens surface 24 .

[0095] Of course, except for the part of the collimated light reflected by multiple reflection surfaces, the rest of the light directly reaches the lens surface 24, and these rest of the light forms the second illumination light projected onto the lens surface 24. "The rest of the light" refers to the light except for the part of the collimated light.

[0096] It should be noted that the second illumination light forms an illumination area in the light distribution pattern, while the first illumination light forms a brightening portion below the light-dark cutoff line of the light distribution pattern.

[0097] In this embodiment, the light on the +Y axis side of the cut-off line forming surface 23 can reach the lens surface 24, and the light on the +Y axis side of the cut-off line forming surface 23 includes the part of the light reflected by the multi-elliptical reflection surface and the remaining light in the collimated light. The light on the -Y axis side of the cut-off line forming surface 23 is reflected by the reflection surface and cannot directly reach the lens surface 24. When this part of the light is reflected by the reflection surface, it becomes the part of the light in the collimated light.

[0098] As described above, the upper surface 230 of the cut-off line forming surface 23 in this embodiment has a step difference, which can be referred to as Figure 2 and Figure 8 As shown, a step difference is formed in the X-axis direction, and the end portion 231 is arranged on a side of the upper surface 230 close to the lens surface 24 .

[0099] Further references Figure 8 As shown, the upper surface has a first step surface 232 and a second step surface 233 spaced apart in the Y-axis direction. The first step surface 232 and the second step surface 233 are sequentially arranged along the X-axis direction and are connected by a connecting surface 234 .

[0100] Furthermore, the shape of the end portion 231 of the cut-off line forming surface corresponds to the cut-off line 3 in the light distribution pattern. Specifically, the upper side of the end portion 231 corresponds to the cut-off line 3 in the light distribution pattern.

[0101] Still reference Figure 7 As shown, the first illumination light passes through the +Z axis side of the end 231 , and the second illumination light passes through the +Y axis side of the end 231 , so that the shape of the end 231 corresponds to the cut-off line 3 in the light distribution pattern.

[0102] Furthermore, the light-guiding structure 2 is an integrated structure formed of transparent materials. This design not only improves the overall aesthetics of the headlamp assembly, but also optimizes its optical performance. The light-guiding structure 2 is made of optical-grade materials with high transparency, such as polycarbonate or acrylic resin. These materials have good light transmittance and weather resistance, and can ensure low light loss during transmission. The design of the integrated structure means that the various parts of the light-guiding structure 2 (including the focusing surface 21, multiple reflection surfaces, the multi-elliptical reflection surface 22, the cutoff line forming surface 23 and the lens surface 24) are integrally formed during the manufacturing process, reducing the assembly error between the components and improving the accuracy of the optical system. In addition, the integrated structure also helps to simplify the assembly process of the headlamp assembly, reduce the manufacturing cost, and improve the reliability of the assembly. This design enables the headlamp assembly to have good economy and practicality while maintaining high performance.

[0103] In this embodiment, the shape of the cut-off line of the light distribution pattern of the illumination light closely corresponds to the shape of the end portion 231 .

[0104] Specifically, the contour of the end 231 on the upper side of the light guide structure 2 directly determines the shape of the light-dark cutoff line 3 in the light distribution pattern. In practical applications, the upper side of the end 231 can be designed as a straight line, a curve or other complex shapes to meet different lighting requirements. Correspondingly, the light-dark cutoff line 3 in the light distribution pattern will also present a shape that matches it, ensuring that the lighting effect meets the design requirements.

[0105] Further, in this embodiment, referring to Figure 3-4 As shown, the lens surface 24 has an optical axis 241 formed in the horizontal direction, that is, formed in the Z axis or in a direction parallel to the Z axis.

[0106] like Figure 4 As shown, the light guide structure 2 has a mounting end 25 arranged relative to the lens surface 24, and the design of the mounting end 25 facilitates the mounting of the light guide structure 2 with other parts of the headlamp assembly, such as the light source 1. A mounting groove 251 is arranged on the mounting end 25, and the mounting groove 251 penetrates the light guide structure 2 in the lateral direction of the light guide structure 2 (in this embodiment, the direction of the X axis or the direction parallel to the X axis). The mounting groove 251 has a first side wall 2511 and a second side wall 2512 located on the upper and lower sides of the optical axis 241, and these two side walls provide incident surfaces for the light emitted by the light source 1 to be incident.

[0107] Furthermore, the bottom of the mounting groove 251 is configured as an arcuate surface 2513 protruding in a direction away from the lens surface 24 . This design helps to optimize the light convergence effect.

[0108] The light-collecting surface 21 includes two light-collecting side walls 211 arranged opposite to each other in the vertical direction, as well as the first side wall 2511, the second side wall 2512 and the arc surface 2513. "Vertical" refers to the Y axis or the direction parallel to the Y axis in this embodiment. The light-collecting side wall 211 extends from the mounting end 25 toward the lens surface 24 and away from the optical axis 241, and the first side wall 2511 and the second side wall 2512 are located between the two light-collecting side walls to ensure that light can be effectively collected.

[0109] The light source 1 is arranged in the mounting groove 251, and emits light to the first side wall 2511, the second side wall 2512 and the arc surface 2513. This layout enables the light emitted by the light source 1 to fully utilize the structural characteristics of the light-collecting surface 21 to form collimated light, which is then reflected and projected through other parts of the light-guiding structure 2, and finally forms a light distribution pattern that meets the design requirements.

[0110] Specifically, the light emitted by the light source 1 is incident from the first side wall 2511 and reaches a light-focusing side wall 211, thereby converging into the collimated light; similarly, the light emitted by the light source 1 is incident from the second side wall 2512 and reaches another light-focusing side wall 211, and can also be converging into the collimated light. Furthermore, after the light emitted by the light source 1 is incident on the curved surface 2513, it can also be converging into the collimated light after being converging through the curved surface 2513.

[0111] It should be noted that the focusing surface 21 in this embodiment is only an example, and in actual applications, other equivalent structures can be used as needed to achieve the same function.

[0112] Multiple reflective surfaces play a vital role in the light guide structure 2, including a first reflective surface 26 and a second reflective surface 27 arranged opposite to each other in the vertical direction. Light emitted by the light source 1 is converged and reflected through different paths, and finally forms a desired light distribution pattern.

[0113] Specifically, refer to Figure 7 As shown, after the light from the light source 1 is incident from the first side wall 2511, it is converged by the focusing side wall 211 to form a first collimated light. At the same time, after the light from the light source is incident from the arc surface 2513, it is also converged into a second collimated light. These two beams of collimated light pass between the first reflecting surface 26 and the second reflecting surface 27 and are directly projected onto the lens surface 24.

[0114] In addition, the light from the light source can also be incident from the second side wall 2512, and converged by another focusing side wall 211 to form a third collimated light. This beam of light is first projected onto the first reflection surface 26, then reflected by the first reflection surface 26 to the second reflection surface 27, and finally reflected by the second reflection surface 27 to the multi-elliptical reflection surface 22. This design ensures that the light can make full use of each part of the light guide structure 2 to form a light distribution pattern that meets the requirements. Of course, other equivalent mechanical structures can also be used in practical applications to achieve the same optical path design.

[0115] In the direction parallel to the optical axis 241, the first reflective surface 26 is carefully arranged at a position relative to the other light-collecting side wall 211. This arrangement ensures that the light can be smoothly projected onto the first reflective surface 26 after being converged by the other light-collecting side wall 211. The first reflective surface 26 has a first end 261 and a second end 262 that are arranged opposite to each other, wherein the first end 261 intersects with the optical axis 241, forming a limit point for light reflection.

[0116] The first reflection surface 26 gradually extends from the first end 261 in a direction away from the lens surface 24 and the optical axis 241 until it reaches the second end 262. This design not only ensures the effective reflection of the light on the first reflection surface 26, but also provides sufficient space for the subsequent propagation path of the light. Of course, in practical applications, the specific shape and extension direction of the first reflection surface 26 can be adjusted as needed to achieve the best optical effect.

[0117] In the design of the first reflective surface 26 and the second reflective surface 27, the angle between them and the optical axis 241 is specially considered to ensure the effective reflection and convergence of light. After precise calculation and optimization, it is determined that the angle between the two reflective surfaces and the optical axis is between 42.5° and 50°. This range not only ensures that the light can be fully reflected, but also avoids optical loss caused by too large or too small angle. In practical applications, the angle can be adjusted within this range according to specific needs to achieve the best optical effect.

[0118] In the light guide structure 2, a light shielding surface 28 is cleverly provided to further optimize the optical performance. Figure 2 and Figure 3 As shown, one end of the shading surface 28 is closely connected to the end 231, ensuring the integrity and stability of the structure. The other end extends toward the lens surface 24 and away from the optical axis 241. Such a design can effectively block stray light, reduce optical interference, and improve the clarity and accuracy of the light distribution pattern. In practical applications, the shape and extension length of the shading surface 28 can be adjusted according to specific needs.

[0119] In this embodiment, reference Figure 8 As shown, the upper surface has a step difference, that is, it has a first step surface 232 and a second step surface 233 spaced apart in the Y-axis direction. The first step surface 232 and the second step surface 233 are sequentially arranged along the X-axis direction and are connected by a connecting surface 234.

[0120] Fig.10 This is a diagram showing the illuminance distribution of the headlamp assembly of this embodiment using contour lines, which is obtained by simulation. "Contour line display" means displaying using contour lines. "Contour lines" are diagrams that connect points of the same value with lines.

[0121] according to Fig.10 It can be seen that the cut-off line 3 of the light distribution pattern is clearly projected. In addition, a light distribution pattern without uneven light distribution can be achieved. In this embodiment, the cut-off line 3 is formed substantially along the X-axis direction. Specifically, Fig.10The cut-off line shown includes a first horizontal segment 31 (located on the -X axis side), a second horizontal segment 32 (located on the +X axis side) and a connecting segment 33. The first horizontal segment 31, the second horizontal segment 32 and the connecting segment 33 correspond to the edge portion of the end portion 231 connected to the first step surface 232, the edge portion of the end portion 231 connected to the second step surface 233 and the edge portion of the end portion 231 connected to the connecting surface 234. The first horizontal segment 31 and the second horizontal segment 32 are substantially straight lines.

[0122] Further references Fig. 9 As shown, the angle between the light shielding surface and the first step surface 232 is a, which is a key parameter that directly affects whether part of the light reflected from the lower side of the multi-elliptical reflective surface 22 can be smoothly projected to the lens surface 24. In order to ensure that this optical path is not blocked, we set a specific range of the angle a.

[0123] In the direction parallel to the optical axis 241 , the distance from the lens surface to the lower end of the multi-elliptical reflecting surface is L, and in the direction perpendicular to the optical axis, the distance from the lower end of the lens surface to the lower end of the second reflecting surface 27 is K.

[0124] In order to ensure the stability and reliability of the optical performance, we set the angle a to satisfy a≤arctan(K / L). This design not only ensures that the shading surface 28 can effectively block stray light, but also ensures that the function of the cutoff line forming surface is not affected, providing good performance and stability for the entire optical system.

[0125] Furthermore, the first step surface 232 is located lower than the second step surface 233, forming an obvious step-like structure. In the design, it is ensured that the vertical distances from the optical axis 241 to the first step surface 232 and to the second step surface 233 are strictly controlled within 0.6 mm or 0.6 mm. In this way, the distance of the light-dark cutoff line relative to the optical axis 241 can be effectively controlled.

[0126] In this embodiment, preferably, the multi-elliptical reflective surface 22 is carefully designed to ensure that the main focus is highly close to the focal position of the lens surface. Specifically, the focus of the multi-elliptical reflective surface 22 is located within the focal plane of the lens surface. Such a design ensures the imaging quality and focusing performance of the optical system and improves the overall optical effect.

[0127] The multi-elliptical reflective surface 22 is extremely finely designed, and includes a multi-elliptical reflective surface body formed by a portion on the side wall of the light guide structure 2. In order to enhance the reflection effect and improve the optical efficiency, a high-performance reflective film is coated on the outer side of the multi-elliptical reflective surface body. This reflective film has excellent reflectivity and durability, and can ensure that light is efficiently and accurately reflected on the multi-elliptical reflective surface 22. The reflective film can be a metal-plated reflective film, a metal dielectric reflective film, etc.

[0128] In this embodiment, the focal position of the lens surface 24 is accurately calculated to ensure that the distance between it and the end 231 is no more than 0.5 mm. This design not only ensures the imaging quality of the optical system, but also improves the focusing performance. During the manufacturing process, strict quality control and technical means are used to ensure that the focal position of the lens surface 24 meets the design requirements, thereby ensuring the consistency and stability of the optical system.

[0129] In summary, the embodiments of the present invention achieve the following technical effects:

[0130] By providing the light guide structure 2 in an integrated manner, the problem of difficult assembly caused by complex parts structure and diverse materials of the headlight assembly is avoided.

[0131] Obviously, the above-described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0132] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0133] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the numbers used in this way can be interchanged where appropriate, so that the embodiments of the present application described herein can be implemented in an order other than those illustrated or described herein.

[0134] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A headlamp assembly, characterized in that: include: A light source, for emitting light; as well as Light guide structure, The light guide structure comprises: A focusing surface, the focusing surface is used to focus the light emitted by the light source and form collimated light; A plurality of reflecting surfaces, used for reflecting part of the collimated light and reflecting the part of the light to a plurality of elliptical reflecting surfaces; A multi-elliptical reflective surface, used for receiving the part of light and reflecting the part of light to the lens surface; A cut-off line forming surface, comprising an upper surface and an end portion, wherein the upper surface forms a step surface in the lateral direction of the light guide structure, and the end portion is disposed on a side of the step surface close to the lens surface; A lens surface, wherein the lens surface is used to project illumination light including the portion of light reflected by the multi-elliptical reflection surface and the remaining light in the collimated light, wherein the light distribution pattern formed after the illumination light is projected includes a light-dark cutoff line corresponding to the end shape, and the portion of light forms a brightening portion below the light-dark cutoff line after being projected through the lens surface.

2. The headlamp assembly according to claim 1, characterized in that: The light-guiding structure is an optical element of an integrated structure formed by transparent materials.

3. The headlamp assembly according to claim 1, characterized in that: The cut-off line has a shape corresponding to a shape of an edge portion connecting the end portion and the upper surface.

4. The headlamp assembly according to claim 1, characterized in that: The lens surface has an optical axis formed in the horizontal direction, the light guide structure has a mounting end arranged relative to the lens surface, and a mounting groove is arranged on the mounting end. The mounting groove penetrates the light guide structure in the lateral direction of the light guide structure and has a first side wall and a second side wall located on the upper and lower sides of the optical axis. The bottom of the mounting groove is arranged to be an arcuate surface protruding in the direction away from the lens surface. The focusing surface includes two focusing side walls arranged opposite to each other in the vertical direction, the first side wall, the second side wall and the arcuate surface. The focusing side wall extends from the mounting end toward the lens surface and away from the optical axis. The first side wall and the second side wall are located between the two focusing side walls. The light source is arranged in the mounting groove and emits the light to the first side wall, the second side wall and the arcuate surface.

5. The headlamp assembly according to claim 4, characterized in that: The multiple reflecting surfaces include a first reflecting surface and a second reflecting surface arranged opposite to each other in the vertical direction. The light of the light source is incident from the first side wall and converged into a first collimated light through a focusing side wall. The light of the light source is incident from the curved surface and converged into a second collimated light. The first collimated light and the second collimated light pass between the first reflecting surface and the second reflecting surface and are projected onto the lens surface. The light of the light source is incident from the second side wall and converged into a third collimated light through another focusing side wall and is then projected onto the first reflecting surface, then reflected from the first reflecting surface to the second reflecting surface, and finally reflected from the second reflecting surface to the multi-elliptical reflecting surface.

6. The headlamp assembly according to claim 5, characterized in that: In a direction parallel to the optical axis, the first reflecting surface is arranged relative to the other light-focusing side wall, and the first reflecting surface has a first end and a second end that are arranged opposite to each other, the first end intersects with the optical axis, and the first reflecting surface extends from the first end to the second end along a direction away from the lens surface and away from the optical axis.

7. The headlamp assembly according to claim 6, characterized in that: The included angles between the first reflecting surface and the second reflecting surface and the optical axis are between 42.5° and 50°.

8. The headlamp assembly according to claim 7, characterized in that: The light-guiding structure further comprises a light-shielding surface, one end of which is connected to the end portion, and the other end of which is extended toward the lens surface and away from the optical axis.

9. The headlamp assembly according to claim 8, characterized in that: The upper surface has a first step surface located on the left side of the light-guiding structure in the horizontal direction and a second step surface located on the right side, the first step surface and the second step surface are both parallel to the optical axis, the angle between the shading surface and the first step surface is a, in the direction parallel to the optical axis, the distance from the lens surface to the lower end of the multi-elliptical reflection surface is L, in the direction perpendicular to the optical axis, the distance between the lower end of the lens surface and the lower end of the second reflection surface is K, and the angle a≤actan(K / L).

10. The headlamp assembly according to claim 9, characterized in that: The first step surface is lower than the second step surface, and the distances from the optical axis to the first step surface and the second step surface are both no greater than 0.6 mm.

11. The headlamp assembly according to claim 1, characterized in that: All focal points of the multi-elliptical reflection surface are located in the focal plane of the lens surface.

12. The headlamp assembly according to claim 1, characterized in that: The multi-elliptical reflective surface comprises a multi-elliptical reflective surface body formed by a portion on the side wall of the light guide structure and a reflective film coated on the outer side of the multi-elliptical reflective surface body.

13. The headlamp assembly according to claim 1, characterized in that: The distance between the focal point of the lens surface and the end portion is no greater than 0.5 mm.

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