Mirror supporting frame

Abstract

The utility model provides a reflector supporting frame with excellent productivity. A concave mirror holder (30) according to the present embodiment is a concave mirror holder (30) which is formed by injection molding and supports a mirror. The concave mirror support (30) has: a base surface (41); and an adhesive surface (42) that is configured from a plurality of convex surfaces with respect to the base surface (41) and that fixes the mirror. The base surface (41) is an injection molded parting line (PL). In addition, a plurality of the adhesive surfaces (42) are arranged in a first direction within the adhesive surfaces (42) and in a second direction orthogonal to the first direction, and the base surfaces (41) are located on the outer edges of the adhesive surfaces (42).

Description

Technical Field

[0001] The utility model relates to a reflector support frame. Background Art

[0002] For example, a display device such as a head-up display includes a reflector for reflecting light emitted from the display. The reflector is supported by a reflector support frame and is rotatable about a rotation axis according to the display position of the displayed image, thereby changing the light emission angle.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: International Publication No. 2019 / 044322 Utility Model Content

[0006] Issues to be solved by utility models

[0007] Reflectors must reflect light in the designed direction. When supported by affixing the reflector to a reflector support frame, the reflective accuracy of the reflector depends on the surface accuracy of the mirror support frame's adhesive surface. However, when the reflector support frame is formed by injection molding, deformation such as center sinking and warping at the ends may occur depending on the molding conditions, potentially requiring subsequent mold adjustments.

[0008] The present invention has been made in consideration of the above-mentioned circumstances, and an object of the present invention is to provide a reflector support frame having excellent productivity.

[0009] Means for solving problems

[0010] In order to solve the above problems, the reflector support frame of the present invention is formed by injection molding and supports the reflector, wherein it has: a base surface; and a fixing surface composed of multiple convex surfaces relative to the base surface, which is used to fix the reflector, and the base surface is the parting line of injection molding.

[0011] Utility model effect

[0012] The reflector support frame and the manufacturing method thereof of the present invention have excellent productivity. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 This is a diagram showing an example of the system configuration of the HUD according to the present embodiment.

[0014] Figure 2 It is a three-dimensional diagram of the concave mirror support frame of the concave mirror unit.

[0015] Figure 3 yes Figure 2A partial enlarged view of the concave mirror support frame.

[0016] Figure 4 It is a cross-sectional view showing a mold for injection molding the bonding surface and a main body formed by the mold.

[0017] Figure 5 It is along Figure 3 Cross-sectional view of line VV.

[0018] Figure 6 It is along Figure 3 A cross-sectional view taken along line VI-VI.

[0019] Figure 7 It is a three-dimensional diagram of the axis.

[0020] Figure 8 This is a cross-sectional view of a mold for insert molding a body and a shaft, and the shaft arranged in the mold, taken along a direction perpendicular to the axis of the shaft.

[0021] Figure 9 This is a cross-sectional view of a mold for insert molding a body and a shaft, and the shaft disposed in the mold, taken along a direction parallel to the axis of the shaft.

[0022] Explanation of symbols

[0023] 1: Head-up display (HUD);

[0024] 2: Vehicle;

[0025] 3: Dashboard;

[0026] 4: Windshield;

[0027] 5: visual observer;

[0028] 8: opening;

[0029] 11: Display unit;

[0030] 12: plane mirror unit;

[0031] 13: concave mirror unit;

[0032] 14: driving unit;

[0033] 15: Control Department;

[0034] 16: Shell;

[0035] 17: lower shell;

[0036] 18: upper shell;

[0037] 19: opening;

[0038] 20: light-transmitting sheet;

[0039] 30: concave mirror support frame (reflector support frame);

[0040] 31: concave mirror (reflector);

[0041] 40: main body;

[0042] 40a: front;

[0043] 40b: back;

[0044] 41: base surface;

[0045] 42: bonding surface (fixing surface);

[0046] 45: Reinforcement ribs;

[0047] 46: Strengthening surface;

[0048] 50: axis;

[0049] 51: side end portion of the supporting member;

[0050] 52: side end of the main body;

[0051] 53: burial part;

[0052] 54: exposed part;

[0053] 55a, 55b: incision;

[0054] 57: end face;

[0055] 60: mold;

[0056] 61: cavity;

[0057] 62: core;

[0058] 63: nested pieces;

[0059] AX: rotation axis;

[0060] DA: visible area;

[0061] L: display light;

[0062] PL: parting line;

[0063] V: virtual image. DETAILED DESCRIPTION

[0064] An embodiment of a reflector support frame and a method for manufacturing the same according to the present invention is described with reference to the accompanying drawings. The reflector support frame and the method for manufacturing the same according to the present invention can be applied to head-up displays (HUDs) mounted on vehicles such as automobiles and two-wheeled vehicles, ships, agricultural machinery, and construction machinery. This embodiment illustrates an example in which the reflector support frame and the reflector unit are mounted on a HUD.

[0065] Figure 1 This is a diagram showing a system configuration example of the HUD 1 equipped with the concave mirror support frame 30 according to the present embodiment.

[0066] The HUD 1 is mounted on the instrument panel 3 of the vehicle 2 and emits display light L from an opening 8 in the instrument panel 3. The HUD 1 projects this display light L onto the windshield 4 of the vehicle 2, which serves as a projection element, from the rear of the vehicle and reflects the light. A visual observer 5 (e.g., the driver), a passenger in the vehicle 2, can visually observe a virtual image V based on the display light L in front of the vehicle relative to the windshield 4 when viewing the windshield 4 from a visible area DA. The display light L indicates, for example, vehicle information such as the vehicle 2's speed, warnings, and route guidance.

[0067] The HUD 1 mainly includes a display unit 11 , a plane mirror unit 12 , a concave mirror unit 13 (reflecting mirror unit), a drive unit 14 , a control unit 15 , and a housing 16 that houses these.

[0068] The display unit 11 is a display that displays images, such as a liquid crystal display, an organic EL display, or a rear projection projector. The display unit 11 displays an image representing vehicle information and emits display light L representing the image.

[0069] The plane mirror unit 12 reflects the display light L emitted from the display section 11 toward the concave mirror unit 13. The concave mirror unit 13 reflects the light reflected by the plane mirror unit 12 toward the windshield 4. The detailed structure of the concave mirror unit 13 will be described later.

[0070] The driving unit 14 is a driving mechanism that rotates the concave mirror unit 13 about the rotation axis AX. The driving unit 14 rotates the concave mirror unit 13 by, for example, rotating a motor.

[0071] The control unit 15 is a control circuit board that controls the display unit 11 and the drive unit 14. The control unit 15 causes the display unit 11 to display an image representing vehicle information. Furthermore, the control unit 15 controls the drive unit 14 to adjust the position of the visible area DA so that it is aligned with the eye level of the visual observer 5. Specifically, the control unit 15 controls the drive unit 14 to rotate the concave mirror unit 13, thereby changing the position of the display light L projected onto the windshield 4 and moving the visible area DA up and down.

[0072] The housing 16 is a black resin housing such as polycarbonate. The housing 16 includes a lower housing 17 and an upper housing 18. The housing 16 houses the display unit 11, the plane mirror unit 12, the concave mirror unit 13, the drive unit 14, and the control unit 15 within a space enclosed by the lower housing 17 and the upper housing 18. The upper housing 18 has an opening 19 for emitting display light L to the outside of the housing 16. The upper housing 18 has a light-transmitting sheet 20 covering the opening 19.

[0073] Next, the structure of the concave mirror unit 13 will be described in detail.

[0074] Figure 2 It is a perspective view of the concave mirror support frame 30 of the concave mirror unit 13.

[0075] Figure 3 yes Figure 2 A partially enlarged view of the concave mirror support frame 30.

[0076] In the following description, “front”, “back”, “up”, “down”, “right” and “left” are used interchangeably. Figure 2 、 3 , 5 and 6, the definitions of "Fr.", "Re.", "To.", "Bo.", "R" and "L" are consistent.

[0077] The concave mirror unit 13 in this embodiment is supported by a support member (not shown) provided on the lower housing 17 for supporting the concave mirror unit 13 in a manner rotatable around a rotation axis AX (predetermined axis). The concave mirror unit 13 mainly includes a concave mirror support frame (reflecting mirror support frame) 30 and a concave mirror 31 ( Figure 1 ).

[0078] The concave mirror support frame 30 supports the concave mirror 31. The concave mirror 31 is fixedly supported by the concave mirror support frame 30.

[0079] The concave mirror support frame 30 includes a main body 40 and a pair of shafts 50 .

[0080] From the perspective of weight reduction and cost reduction, the main body 40 is made of a resin such as polybutylene terephthalate and is formed by injection molding. The main body 40 has a substantially rectangular shape that is long in the left-right direction along the rotation axis AX and short in the vertical direction compared to the left-right direction, and has a concave shape from the front to the rear. The main body 40 has a front face 40a facing forward and a back face 40b facing rearward ( Figure 5 The front surface 40a is a surface on which the concave mirror 31 is fixed.

[0081] The front surface 40a has a base surface 41 and a bonding surface (fixing surface) 42. The base surface 41 is located at the outer edge of each bonding surface 42 and becomes the parting line PL ( Figure 4 ) face.

[0082] The adhesive surface 42 is a plurality of convex surfaces that protrude forward by a predetermined amount (e.g., 1 mm) relative to the base surface 41. The adhesive surface 42 is a surface for fixing the concave mirror 31 by double-sided tape or adhesive. A plurality of adhesive surfaces 42 are arranged in the left-right direction (first direction) and the up-down direction (second direction orthogonal to the first direction) within the base surface 41. Figure 2 In FIG, five adhesive surfaces 42 are arranged in the left-right direction and two are arranged in the up-down direction.

[0083] Here, Figure 4 4 is a cross-sectional view showing a mold 60 for injection-molding the adhesive surface 42 and the main body 40 formed by the mold 60 .

[0084] Mold 60 includes a mother mold, which is composed of a cavity 61 and a core 62, and a plurality of nested pieces 63 positioned relative to the mother mold. These nested pieces 63 are used to form bonding surfaces 42, and are, for example, a number of nested pieces 63 corresponding to the number of bonding surfaces 42. Alternatively, these nested pieces 63 are capable of simultaneously forming multiple bonding surfaces 42 (e.g., two).

[0085] A pair of shafts 50 are fixed to the main body 40 at the left and right ends thereof along the rotation axis AX. Each shaft 50 is supported by a support member formed by a structure of the lower housing 17. Each shaft 50 is made of metal. The pair of shafts 50 are integrally formed with the main body 40 by insert molding.

[0086] As a method for attaching the shaft 50 to the main body 40, one approach is to press-fit the shaft 50 into the main body 40, which is formed with an insertion opening for the shaft 50. However, if the main body 40 is formed of resin, there is a risk that stress during press-fitting may cause cracks, or the shaft 50 may be inserted with an axial displacement. Therefore, the concave mirror support frame 30 of this embodiment forms the shaft 50 integrally with the main body 40 through insert molding. This allows the concave mirror support frame 30 to maintain productivity even when the main body 40 is formed of a material such as resin that is less rigid than metal.

[0087] Figure 5 It is along Figure 3 Cross-sectional view of line VV. Figure 6 It is along Figure 3 A cross-sectional view taken along line VI-VI. Figure 7 It is a perspective view of the shaft 50 .

[0088] Each shaft (each pair of shafts) 50 has a support member side end portion 51 and a main body side end portion 52. The support member side end portion 51 is a portion that protrudes from the main body 40 and is supported by the support member. The main body side end portion 52 is an end opposite to the support member side end portion 51. Each shaft 50 has an embedded portion 53 and an exposed portion 54 between the support member side end portion 51 and the main body side end portion 52. The embedded portion 53 is a portion that is covered by the main body 40 and embedded in the main body 40 and cannot be visually observed. The exposed portion 54 is a portion that is closer to the main body side end portion 52 than the embedded portion 53, and is a portion that is at least partially exposed from the main body 40.

[0089] Each shaft 50 has a concavo-convex shape on the surface of the embedded portion 53 to prevent it from falling off relative to the main body 40. The concavo-convex shape is, for example, Figure 7 As shown, there are two notches 55a and 55b. Notch 55a is a concave portion formed continuously along the circumferential direction on both the support member end 51 side and the main body end 52 side. Notch 55b is a concave portion formed axially to connect notches 55a. In addition, the concave and convex shapes can be formed in various shapes and positions through straight knurling, cross-knurling, cutting, and other processes.

[0090] In addition, in relation to each shaft 50, the main body 40 has a reinforcing rib 45 on the exposed portion 54 of each shaft 50. The reinforcing rib 45 is a rib that extends in the axial direction on the surface of each shaft 50 and supports it in the radial direction. Specifically, the reinforcing rib 45 is arranged at 90-degree intervals in the circumferential direction on the surface of each shaft 50. In addition, the main body 40 has a reinforcing surface 46 ( Figure 5 ). The reinforcement surface 46 is a surface that is orthogonal to the reinforcement rib 45 and supports each shaft 50 in the axial direction at the end surface 57 of the main body side end 52. Since the main body 40 is formed of resin and has an exposed portion 54, the rigidity is reduced compared to the case where it is formed of metal such as magnesium alloy, and there is a possibility that the vibration resistance during use will be impaired. In addition, when the bearing is installed on the shaft 50 by press-fitting, a strong force is applied to the shaft 50, but this force also affects the main body 40, and may cause buckling. In contrast, the concave mirror support frame 30 of this embodiment has reinforcement ribs 45 and reinforcement surface 46 on the exposed portion 54 and the end surface 57 of the main body side end 52. As a result, the concave mirror support frame 30 can have the required rigidity without relying on the material of the main body 40. That is, the concave mirror support frame 30 can improve the vibration resistance during use by the reinforcement ribs 45 and reinforcement surface 46, and can also reduce the impact of the bearing on the main body 40 side when it is pressed into.

[0091] Figure 8 The figure shows a mold 60 for insert-molding the main body 40 and the shaft 50 and the shaft 50 disposed in the mold 60 , and is a cross-sectional view taken along a direction perpendicular to the axis of the shaft 50 . Figure 9The figure shows a mold 60 for insert-molding the main body 40 and the shaft 50 and the shaft 50 disposed in the mold 60 , and is a cross-sectional view taken along a direction parallel to the axis of the shaft 50 .

[0092] Each shaft 50 has an exposed portion 54, so that during insert molding, it can have a region 58 that pairs with the support member side end portion 51 and is directly arranged in the mold 60. Therefore, it is easy to arrange each shaft 50 in the mold 60 during insert molding, and the workability during molding can be improved.

[0093] Here, the bonding surface 42 of the main body 40 is the portion that must accurately support the concave mirror 31 in order for the display light L to be reflected as designed by the concave mirror 31. Therefore, the concave mirror support frame 30 of this embodiment forms the bonding surface 42 with the nested piece 63 rather than the master mold, thereby improving the productivity of the bonding surface 42. In other words, if surface accuracy cannot be achieved through injection molding and subsequent adjustment of the mold 60 is required, only the nested piece 63 at the required location can be adjusted, rather than the entire master mold. Therefore, the concave mirror support frame 30 of this embodiment has excellent productivity.

[0094] While several embodiments of the present invention have been described, these embodiments are provided as examples and are not intended to limit the scope of the claims. These novel embodiments may be implemented in various other ways, and various omissions, substitutions, and modifications may be made without departing from the scope of the present invention. These embodiments and their variations are intended to be within the scope and spirit of the present invention and encompassed by the present invention and its equivalents as set forth in the claims.

Claims

1. A reflector support frame formed by injection molding and supporting a reflector, characterized in that: have: base surface; and a fixing surface, which is composed of a plurality of convex surfaces relative to the base surface and is used to fix the reflector, The base surface is the parting line of the injection molding.

2. The reflector support frame according to claim 1, wherein: The plurality of fixing surfaces are arranged in a first direction within the fixing surface and in a second direction perpendicular to the first direction. The base surface is located at the outer edge of each of the fixing surfaces.

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