Connection structure of lens and light type baffle

Abstract

The connection structure between the lens and the beam pattern baffle includes an inner lens, a beam pattern baffle, and a connecting seat. The beam pattern baffle is mounted on the connecting seat, which is connected to the inner lens. The inner lens has an entrance surface and an exit surface. The entrance surface has a light-shielding area and a light-entry area. The light-shielding area has an opaque material to block light, and light entering from the light-entry area 13 can exit from the light-entry surface. The beam pattern baffle has a light-guiding surface and a cutoff profile. The light-guiding surface is set along the direction of light illumination, and the cutoff profile is a straight line projected onto the entrance surface along the direction of light illumination. The beam pattern baffle is directly fixed to the lens, resulting in higher accuracy in the relative position between the beam pattern baffle and the lens, a flatter beam pattern cutoff line, and a simple structure. Even with temperature changes, it is not prone to significant deformation that could cause a shift in the relative position. The light-shielding area blocks stray light, resulting in a clearer beam pattern profile and a clearer beam pattern cutoff line, making operation more convenient.

Description

Technical Field

[0001] This application relates to the field of automotive lighting components, and in particular to the connection structure of lenses and light pattern baffles. Background Technology

[0002] In existing low-beam lens modules, the assembly of the beam pattern baffle and the lens presents numerous problems. These include insufficient positioning accuracy; the baffle is fixed at a single point using screws or clips, making it prone to shifting due to thermal expansion or vibration, affecting the clarity of the cutoff line; stray light control is difficult, with light leakage at the gap between the baffle and the lens causing glare above the beam pattern; poor thermal stability, with plastic baffles easily deforming at high temperatures, and metal baffles interfering with the lens's optical performance due to heat conduction; and high assembly complexity, with multiple parts installed independently—the beam pattern baffle, bracket, and heat sink are all manufactured and installed separately—resulting in cumbersome processes and accumulated tolerances affecting beam pattern consistency. Furthermore, the cutoff line height of the headlight needs to be achieved by driving the headlight to rotate or moving the beam pattern baffle via a drive device, resulting in a complex structure and high cost.

[0003] Chinese patent application CN110081384A, entitled "LED Headlight Lens Bracket with Light-Blocking Function Achieved by Local Electroplating," discloses an LED headlight lens bracket that achieves light-blocking function using local electroplating. It includes a lens bracket connecting a lens assembly, with a reflective cavity within the bracket and a local electroplated layer inside the cavity. This patented lens bracket is integrally injection molded from plastic, and local electroplating is performed in the reflective cavity to form the local electroplated layer, directly forming it on the surface of the lens bracket. This eliminates the need for a light-blocking plate, simplifying the structure and installation process of the light-blocking cloth. However, this patent is designed for single-lens headlights, and the connection between the light-blocking plate and the lens via the bracket increases assembly tolerances. For multi-lens headlights, fixing multiple lenses to the same bracket is more complex. Utility Model Content

[0004] This application provides a connection structure for a lens and a light pattern baffle to at least solve one of the above-mentioned technical problems existing in the prior art.

[0005] According to this application, a connection structure for a lens and a light pattern baffle is provided, including an inner lens, a light pattern baffle, and a connecting seat. The light pattern baffle is disposed on the connecting seat, and the connecting seat is connected to the inner lens. The inner lens has an incident light surface and an exit light surface. The incident light surface has a light-shielding area and an incident light area. The light-shielding area has an opaque material that can block light. Light entering from the incident light area can exit from the exit light surface. The light pattern baffle has a light-guiding surface and a cutoff contour line. The light-guiding surface is arranged along the light irradiation direction, and the cutoff contour line is a straight line projected onto the incident light surface along the light irradiation direction.

[0006] Compared with the prior art, the connection structure of the lens and the light pattern baffle in this application has the following advantages:

[0007] The beam pattern baffle is directly fixed to the lens, which makes the relative position of the beam pattern baffle and the lens more accurate, the resulting beam pattern cutoff line is flatter, the structure is simple, and even with temperature changes, it is not easy to undergo large deformations that would cause the relative position to shift. The setting of the light-blocking area can block stray light, and the final beam pattern outline and beam pattern cutoff line are clearer, making it easier to operate.

[0008] In one embodiment, the connector and the inner lens are connected by a snap, screw or bolt, or by bonding, hot riveting, ultrasonic welding or magnetic attraction, which makes the connection more stable.

[0009] In one embodiment, the inner lens and the connecting seat are connected by an elastic metal strip, which allows the inner lens and the connecting seat to bend the elastic metal strip during installation. The inner lens is provided with a locking hole, and the connecting seat is provided with a first protrusion. By bending the elastic metal strip, the first protrusion can be inserted into the locking hole, thus achieving one-piece injection molding, solving the mold opening angle problem, and then inserting and installing after injection molding.

[0010] In one embodiment, there is a certain gap between the first protrusion and the locking hole, which allows the first protrusion to move up and down or rotate relative to the locking hole within a certain range. The elastic metal strip is a shape memory alloy, so that the light pattern baffle has two positions relative to the inner lens and the light source, one high and one low, which can be adjusted in real time according to different needs to meet the height requirements of different light patterns.

[0011] In one embodiment, the light-incident area is provided with a multi-microlens array on the light-incident surface, so that the light output is more uniform, avoiding the light from being concentrated in the central area, and making the brightness difference between the central area and the outer area smaller.

[0012] In one embodiment, the inner lens and the bracket are integrally injection molded to form an integral structure. The bracket is provided with elastic hooks or side protrusions for installation by snap-fit, which can reduce the number of parts and increase assembly accuracy.

[0013] In one embodiment, the bracket has a front mounting part that matches the outer lens. The outer lens and the bracket are connected by a snap, screw or bolt, or by bonding, hot riveting, ultrasonic welding or magnetic attraction. This can improve the relative positional accuracy between the outer lens and the inner lens, thereby reducing the number of parts and increasing installation accuracy.

[0014] In one embodiment, both the inner and outer lenses are cylindrical lenses, with the focal line of the inner lens perpendicular to that of the outer lens. This reduces the lens thickness and the overall weight of the headlight.

[0015] In one embodiment, the light-patterned baffle is in the shape of an arc-shaped thin sheet, and the connecting seat has a concave arc-shaped surface. The light-patterned baffle is installed on the arc-shaped surface. The light-patterned baffle is made of shape memory alloy material, so that the light-patterned baffle is in a first shape and the cutoff contour line is at a first height at room temperature, and after heating, the light-patterned baffle is in a second shape and the cutoff contour line is at a second height. In this way, the height of the light-patterned cutoff line can be changed by the light-patterned baffle according to the vehicle condition.

[0016] In one embodiment, the connecting seat has an arc-shaped convex light-blocking surface and a flat positioning end face. The light-blocking surface can block stray light, and the positioning end face can interact with other structures to form a better positioning function.

[0017] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of this application, nor is it intended to limit the scope of this application. Other features of this application will become readily apparent from the following description. Attached Figure Description

[0018] The above and other objects, features, and advantages of exemplary embodiments of this application will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings. Several embodiments of this application are illustrated in the drawings by way of example and not limitation, in which:

[0019] In the accompanying drawings, the same or corresponding reference numerals indicate the same or corresponding parts.

[0020] Figure 1 This paper shows a schematic diagram of the connection structure between the lens and the light pattern baffle in Embodiment 1 of this application;

[0021] Figure 2 An exploded view of the connection structure between the lens and the light pattern baffle in Embodiment 1 of this application is shown;

[0022] Figure 3 This is a half-sectional view showing the cutoff profile of the connection structure between the lens and the light pattern baffle in Embodiment 1 of this application at a first height;

[0023] Figure 4 A half-sectional view of the connection structure of the lens and the light pattern baffle in Embodiment 1 of this application is shown at a second height;

[0024] Figure 5 This paper shows a schematic diagram of the connection structure between the lens and the light pattern baffle in Embodiment 2 of this application;

[0025] Figure 6 An exploded view of the connection structure between the lens and the light pattern baffle in Embodiment 2 of this application is shown;

[0026] Figure 7This paper shows a schematic diagram of the connection structure between the lens and the light pattern baffle in Embodiment 3 of this application;

[0027] Figure 8 This diagram shows the initial state of the connection structure between the lens and the light pattern baffle in Embodiment 3 of this application after injection molding;

[0028] Figure 9 This diagram shows the injection-molded assembly state of the connection structure between the lens and the light pattern baffle in Embodiment 3 of this application;

[0029] Figure 10 This paper shows a schematic diagram of the connection structure between the lens and the light pattern baffle in Embodiment 4 of this application;

[0030] Figure 11 The diagram shows an assembly schematic of the inner lens and the light pattern baffle of the connection structure of the lens and the light pattern baffle in Embodiment 4 of this application.

[0031] Explanation of the labels in the diagram:

[0032] X, first direction; Y, second direction; Z, third direction;

[0033] 1. Inner lens; 2. Light pattern baffle; 3. Connecting seat; 4. Locking pin; 5. Bracket; 6. Outer lens; 10. Light-emitting surface; 11. Light-entry surface; 12. Light-shielding area; 13. Light-entry area; 14. Support structure; 15. Support protrusion; 16. First lug; 17. Second lug; 18. Limiting slot; 19. Locking hole; 20. Elastic metal strip; 21. Light guide surface; 22. Cut-off contour line; 23. Barbed structure; 31. Arc-shaped surface; 32. Light-shielding surface; 33. Positioning end face; 34. Elastic wedge-shaped hook; 51. Elastic hook; 52. Side protrusion. Detailed Implementation

[0034] To make the objectives, features, and advantages of this application more apparent and understandable, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0035] like Figure 1 and Figure 3As shown, the connection structure of the lens and the light pattern baffle includes an inner lens 1, a light pattern baffle 2, and a connecting seat 3. The light pattern baffle 2 is disposed on the connecting seat 3, and the connecting seat 3 is connected to the inner lens 1. The inner lens 1 has an incident light surface 11 and an exit light surface 10. The incident light surface 11 has a light-shielding area 12 and a light-incident area 13. The light-shielding area 12 is provided with an opaque material that can block light. Light entering from the light-incident area 13 can be emitted from the light-incident surface 10. The light pattern baffle 2 has a light-guiding surface 21 and a cutoff contour line 22. The light-guiding surface 21 is arranged along the light irradiation direction, and the cutoff contour line 22 is a straight line projected onto the incident light surface 11 along the light irradiation direction.

[0036] In one embodiment, the connecting seat 3 and the inner lens 1 are connected by a snap fastener, screw or bolt, or by adhesive bonding, thermal riveting, ultrasonic welding, fusion welding or magnetic attraction.

[0037] Example 1:

[0038] like Figure 1 and Figure 3 As shown, the inner lens 1 is provided with a support structure 14, which can be set along a first direction or a second direction. In this embodiment, the support structure 14 is set along the first direction. Support protrusions 15 are provided on the upper and lower sides of the inner lens 1 in the figure, with a height of 1.5-2.5mm, for cooperating with the lamp housing positioning groove, with a tolerance of ±0.05mm.

[0039] like Figure 1 and Figure 2 As shown, the inner lens 1 is integrally provided with a first lug 16 and a second lug 17 in the second direction, that is, on the left and right sides of the figure. The first lug 16 and the second lug 17 are provided with a limiting groove 18 in the center to form a buckle structure. The connecting seat 3 is provided with a barb structure 23 on the left and right sides in the second direction. The first lug 16 and the second lug 17 are made of elastic material and have a certain elasticity. In some embodiments, the buckle structure can be provided on the left and right sides of the connecting seat 3, and the inner lens 1 is provided with a barb structure.

[0040] like Figure 1 and Figure 2 As shown, the light-emitting surface 10 is a freeform surface used for collimating the main beam, with a radius of curvature R = 50-150mm. The light-incident surface 11 is designed with two sections: a light-shielding area 12 and a light-incident area 13. The surface of the light-shielding area 12 is coated with a black matte coating with a reflectivity of ≤5%, covering an area of ​​30-40%. The light-incident area 13 uses a microlens array with a unit size of 0.5×0.5mm to homogenize the light output from the LED light source.

[0041] like Figure 3 and Figure 4As shown, in one embodiment, the light-patterned baffle 2 is an arc-shaped thin sheet, and the connecting seat 3 has a concave arc-shaped surface 31. The light-patterned baffle 2 is installed on the arc-shaped surface 31, and the lower end of the light-patterned baffle 2 is fixedly connected to the connecting seat 3. The fixed connection method includes snap-fit, screw, riveting, heat fusion, etc. Figure 3 As shown, the light-patterned baffle 2 is made of shape memory alloy material, so that at room temperature the light-patterned baffle 2 is in the first shape and the cutoff contour line 22 is at the first height, as shown. Figure 4 As shown, after heating, the light-patterned baffle 2 takes on a second shape and the cutoff contour line 22 is at a second height.

[0042] In one embodiment, the connecting seat 3 has an arc-shaped, outwardly convex light-blocking surface 32 and a flat positioning end face 33. The radius of curvature R of the arc-shaped surface 31 is 3-8 mm, which matches the curvature of the light-incident area 13, and the gap is ≤0.1 mm.

[0043] The cutoff profile 22 has an inclination angle of 15°±0.5°, and the edge roughness Ra of the light-patterned baffle 2 is ≤0.05mm. It is formed by precision stamping or laser cutting. The cutoff profile 22 is projected onto the light-entry area 13 and coincides with the edge of the light-entry area 13 to ensure efficient light transmission.

[0044] like Figure 1 and Figure 2 As shown, the support protrusion 15 engages with the lamp housing slot to restrict displacement in the first and / or second directions.

[0045] After the first lug 16 and the second lug 17 are fastened together, they are lifted and fixed by the locking pin 4. The inner lens 1 or the connecting seat 3 is provided with a threaded hole to match the locking pin 4. The distance between the inner lens 1 and the connecting seat 3 is adjusted by the locking pin 4 to form support. The buckle can provide a pre-tightening force of 5-10N to compensate for thermal expansion.

[0046] The inner lens 1 uses PMMA substrate with a light transmittance of ≥92%. After injection molding, a black nano-ceramic coating is sprayed onto the light-shielding area 12. The supporting protrusion 15 is formed using a metal insert mold, with a height tolerance controlled within ±0.03mm. Alternatively, it can be integrally injection molded using the same material as the inner lens 1. The light pattern baffle 2 is made of 6061 aluminum alloy, anodized, and the cutoff contour line 22 is processed by five-axis laser cutting.

[0047] During assembly, the inner lens 1 is positioned to the lamp housing via the support protrusion 15. The barbed structure 23 of the light pattern baffle 2 engages with the first lug 16 of the inner lens 1 and is then locked in place by the locking pin 4, with a torque of 1.2-1.5 N·m. Check that the cutoff contour line 22 is aligned with the light pattern projection.

[0048] In one embodiment, the light-incident area 13 is provided with a plurality of microlens arrays on the light-incident surface 11.

[0049] Example 2:

[0050] like Figure 5 and Figure 6 As shown, the lower end of the inner lens 1 in the first direction is provided with a locking hole 19, the cross-section of which is convex. The connecting seat 3 is provided with an elastic wedge-shaped hook 34, which has an inclined surface. When the elastic wedge-shaped hook 34 is inserted into the locking hole 19, it can bend along the first direction. When the elastic wedge-shaped hook 34 is fully inserted, it can be reset. The inner lens 1 is provided with a locking pin 4, which can maintain a certain locking force between the inner lens 1 and the connecting seat 3 to prevent loosening.

[0051] Example 3:

[0052] like Figure 7 and Figure 8 As shown, in one embodiment, the inner lens 1 and the connecting seat 3 are connected by an elastic metal strip 20, so that the inner lens 1 and the connecting seat 3 can be bent during installation. The inner lens 1 is provided with a locking hole 19, and the connecting seat 3 is provided with a first protrusion 35. By bending the elastic metal strip 20, the first protrusion 35 can be inserted into the locking hole 19.

[0053] In one embodiment, a certain gap exists between the first protrusion 35 and the locking hole 19, allowing the first protrusion 35 to move up and down or rotate relative to the locking hole 19 within a certain range. The elastic metal strip 20 is a shape memory alloy. After heating, it can restore its shape before deformation. Due to the magnification effect, even if the light pattern baffle 2 moves only a few millimeters, the height change of the light pattern cutoff line can reach tens of centimeters, which can meet the adjustment needs.

[0054] like Figure 8 As shown, during the injection molding of the inner lens 1 and the light pattern baffle 2, the first protrusion 35 forms a 90-degree angle with the card hole 19. When the draft direction of the light pattern baffle 2 is the same as the direction of the first protrusion 35, the first protrusion 35 forms a 180-degree angle with the card hole 19 during injection molding.

[0055] like Figure 9 As shown, after the inner lens 1 and the light pattern baffle 2 are injection molded, the first protrusion 35 is inserted into the card hole 19 to complete the assembly. The relative position of the inner lens 1 and the light pattern baffle 2 is affected by temperature and other contacting components. For example, the heat-conducting mounting bracket can restrict the position of the light pattern baffle 2.

[0056] Example 4:

[0057] like Figure 10 and Figure 11 As shown, in one embodiment, the inner lens 1 and the bracket 5 are integrally injection molded to form an integral structure, and the bracket 5 is provided with an elastic hook 51 or a side protrusion 52 for installation by snap-fit.

[0058] In one embodiment, the bracket 5 has a front mounting part that matches the outer lens. The outer lens and the bracket 5 are connected by a snap, screw or bolt, or by adhesive, thermal riveting, ultrasonic welding or magnetic attraction.

[0059] In one embodiment, both the inner lens 1 and the outer lens 6 are cylindrical lenses, and the focal line of the inner lens 1 is perpendicular to the focal line of the outer lens 6.

[0060] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A connection structure between a lens and a beam pattern baffle, characterized in that: The device includes an inner lens (1), a light pattern baffle (2), and a connecting seat (3). The light pattern baffle (2) is disposed on the connecting seat (3), which is connected to the inner lens (1). The inner lens (1) has an incident light surface (11) and an exit light surface (10). The incident light surface (11) has a light-shielding area (12) and an incident light area (13). The light-shielding area (12) is provided with an opaque material that can block light. Light entering from the incident light area (13) can be emitted from the exit light surface (10). The light pattern baffle (2) has a light guide surface (21) and a cutoff contour line (22). The light guide surface (21) is disposed along the direction of light irradiation, and the cutoff contour line (22) is projected onto the incident light surface (11) as a straight line along the direction of light irradiation.

2. The connection structure of the lens and the beam pattern baffle according to claim 1, characterized in that: The connecting seat (3) and the inner lens (1) are connected by a buckle, screw or bolt, or by bonding, hot riveting, welding, fusion or magnetic attraction.

3. The connection structure of the lens and the beam pattern baffle according to claim 1, characterized in that: The inner lens (1) and the connecting seat (3) are connected by an elastic metal strip (20) so that the inner lens (1) and the connecting seat (3) can be bent during installation. The inner lens (1) is provided with a locking hole (19) and the connecting seat (3) is provided with a first protrusion (35). By bending the elastic metal strip (20), the first protrusion (35) can be inserted into the locking hole (19).

4. The connection structure of the lens and the beam pattern baffle according to claim 3, characterized in that: There is a certain gap between the first protrusion (35) and the card hole (19) so that the first protrusion (35) can move up and down or rotate relative to the card hole (19) within a certain range. The elastic metal strip (20) is a shape memory alloy.

5. The connection structure of the lens and the beam pattern baffle according to any one of claims 1-4, characterized in that: The light-incident area (13) is provided with a plurality of microlens arrays on the light-incident surface (11).

6. The connection structure of the lens and the beam pattern baffle according to claim 5, characterized in that: The inner lens (1) and the bracket (5) are integrally injection molded to form an integral structure. The bracket (5) is provided with an elastic hook (51) or a side protrusion (52) for installation by snap-fit.

7. The connection structure of the lens and the beam pattern baffle according to claim 6, characterized in that: The bracket (5) is provided with a front mounting part that matches the outer lens (6). The outer lens (6) and the bracket (5) are connected by a buckle, screw or bolt, or by adhesive, hot riveting, welding or magnetic attraction.

8. The connection structure of the lens and the beam pattern baffle according to claim 7, characterized in that: Both the inner lens (1) and the outer lens (6) are cylindrical lenses, and the focal line of the inner lens (1) is perpendicular to the focal line of the outer lens (6).

9. The connection structure of the lens and the beam pattern baffle according to claim 1, characterized in that: The light-shaped baffle (2) is in the shape of an arc-shaped thin sheet. The connecting seat (3) is provided with a concave arc-shaped surface (31). The light-shaped baffle (2) is installed on the arc-shaped surface (31). The light-shaped baffle (2) is made of shape memory alloy material, so that at room temperature the light-shaped baffle (2) is in the first shape and the cutoff contour line (22) is at the first height. After heating, the light-shaped baffle (2) is in the second shape and the cutoff contour line (22) is at the second height.

10. The connection structure of the lens and the beam pattern baffle according to claim 9, characterized in that: The connecting seat (3) is provided with an arc-shaped convex light-blocking surface (32) and a flat positioning end face (33).

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