Optical component, vehicle lamp, and method for manufacturing optical component
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- KOITO MFG CO LTD
- Filing Date
- 2024-07-12
- Publication Date
- 2026-06-03
AI Technical Summary
Existing vehicle headlamps with metal reflectors face issues of increased weight and material costs, and high temperatures due to sunlight condensation, which can deform components and affect light distribution accuracy.
A vehicle headlamp design using a resin-made first reflector, a metal shade, and a metal second reflector, with specific fixing portions to manage thermal expansion and maintain light distribution accuracy.
The design reduces weight and improves heat resistance, ensuring accurate light distribution patterns despite thermal challenges.
Smart Images
Figure IMGAF001_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present disclosure relates to an optical component, for example, an optical component used in a vehicle lamp.BACKGROUND ART
[0002] In the related art, there is known a vehicle headlamp including a light emitting device array including a plurality of semiconductor light emitting devices capable of irradiating a plurality of individual irradiation areas divided in a left-right direction above a horizontal line. For example, there has been proposed a vehicle headlamp including a light emitting device array in which a plurality of light emitting devices each having an individual irradiation area constituting a high-beam light distribution pattern and configured to be individually turned on are mounted in a row on a substrate, a projection lens disposed in front of the light emitting device array, and a reflector disposed below the light emitting device array (see Patent Literature 1).CITATION LISTPATENT LITERATURE
[0003] Patent Literature 1: Pamphlet of International Publication No. WO16 / 013447SUMMARY OF INVENTIONTECHNICAL PROBLEM
[0004] However, since the entire reflector provided in the vehicle headlamp described above is a component made of metal, the weight of components tends to increase and material costs also tend to increase. On the other hand, when sunlight is incident from an outside through the projection lens and condensed in the lamp, the temperature of a condensing portion becomes high, so that a portion which can be the condensing portion is required to have heat resistance.
[0005] An exemplary object of the present disclosure is to provide a new optical component that is reduced in weight while satisfying desired performance such as light distribution and heat resistance.SOLUTION TO PROBLEM
[0006] In order to solve the above problem, an optical component according to an aspect of the present disclosure includes: a first reflector made of a resin material; a shade made of a metal material and assembled to the first reflector; and a second reflector made of a metal material and assembled to the first reflector. The first reflector includes a main body that is plate-shaped and in which an opening through which light emitted from a light source passes is formed, and a first reflection portion provided around the opening and configured to reflect, toward a front side of a vehicle, a part of light passing through the opening. The shade is provided to cross the opening when viewed from the front side of the vehicle, and configured to block a part of light passing through the opening to form a cut line of a light distribution pattern, and the second reflector includes a second reflection portion provided on a side opposite to the first reflection portion across the shade to close a part of the opening and configured to reflect, toward the front side of the vehicle, a part of light passing through the opening. The main body includes a first fixing portion to which the shade is assembled and fixed from a first direction, and a second fixing portion to which the second reflector is assembled and fixed from a second direction different from the first direction.
[0007] According to this aspect, since the first reflector is made of a resin material, the weight of the optical component can be reduced as compared with a case of a metal member as a whole. On the other hand, the heat resistance can be improved by forming the shade and the second reflector with a metal material.
[0008] The first fixing portion is a pair of bosses to be thermally caulked, and the shade may include a positioning hole positioned with respect to the main body when one of the pair of bosses enters, and an elongated hole into which the other of the pair of bosses enters. Accordingly, even if there is a difference in a thermal expansion coefficient between the first reflector made of the resin material and the shade made of the metal material, the shade assembled to the first fixing portion is less likely to be deformed by the heat.
[0009] The second fixing portion may be provided below the first fixing portion in a vehicle up-down direction and on both sides of the opening in a vehicle width direction.
[0010] The second fixing portion is a pair of bosses to be thermally caulked, and the second reflector may include a positioning hole positioned with respect to the main body when one of the pair of bosses enters, and an elongated hole into which the other of the pair of bosses enters. Accordingly, even when there is a difference in the thermal expansion coefficient between the first reflector made of the resin material and the second reflector made of the metal material, the second reflector assembled to the second fixing portion is less likely to be deformed due to the heat.
[0011] The shade may be fixed to the first fixing portion in a state in which a rear end in a vehicle front-rear direction extends into the opening. Accordingly, a depth of the shade can be extended even when a tip portion of the shade cannot be made forward due to the restriction of a desired light distribution pattern. Therefore, even when the shade is temporarily thin, the entire strength can be secured.
[0012] The second reflector may be fixed to the second fixing portion in a state in which the rear end in the vehicle front-rear direction extends into the opening.
[0013] Another aspect of the present disclosure relates to a vehicle lamp. The vehicle lamp includes a light source in which a plurality of light emitting devices are disposed, the optical component described above, and a projection lens that projects, toward a front side of a vehicle, light emitted from the light source and passed through the opening of the optical component. The optical component is configured to form a first light distribution pattern by light passing between the first reflector and the shade, and form a second light distribution pattern by light passing between the shade and the second reflector.
[0014] According to this aspect, even when sunlight is incident from the outside through the projection lens and condensed in the lamp, the shade formed of the metal member has high heat resistance and is hardly deformed, so that a light distribution pattern with high accuracy can be realized.
[0015] Another aspect of the present disclosure relates to a method for manufacturing an optical component. The method is a method for manufacturing an optical component including a first reflector made of a resin material, a shade made of a metal material and assembled to the first reflector, and a second reflector made of a metal material and assembled to the first reflector. The method includes: a step of preparing the first reflector including a main body that is plate-shaped and in which an opening through which light emitted from a light source passes is formed and a first reflection portion provided around the opening and configured to reflect, toward a front side of a vehicle, a part of light passing through the opening; a first assembling step of assembling the shade from a lower side in a vehicle up-down direction to a first fixing portion provided in the main body, the shade being provided to cross the opening when viewed from the front side of the vehicle and configured to block a part of light passing through the opening to form a cut line of a light distribution pattern; and a second assembling step of assembling the second reflector to a second fixing portion provided in the main body from a front side in a vehicle front-rear direction, the second reflector including a second reflection portion provided on a side opposite to the first reflection portion across the shade to close a part of the opening and being configured to reflect, toward the front side of the vehicle, a part of light passing through the opening.
[0016] According to this aspect, even when the shade is detached from the first reflector, it is possible to prevent the shade from falling downward as it is by the second reflector.
[0017] Any combination of the above components, and a conversion of the expressions of the present disclosure into a manufacturing method, a device such as a lamp or lighting device, a light-emitting module, a light source, and the like are also valid aspects of the present disclosure.ADVANTAGEOUS EFFECTS OF INVENTION
[0018] According to the present disclosure, it is possible to realize a new optical component with reduced weight.BRIEF DESCRIPTION OF DRAWINGS
[0019] [FIG. 1] FIG. 1 is a side view showing a schematic configuration of a vehicle lamp according to an embodiment of the present invention. [FIG. 2] FIG. 2 is a perspective view of a main part of a vehicle lamp unit according to the present embodiment. [FIG. 3] FIG. 3 is an exploded perspective view of the vehicle lamp unit shown in FIG. 2. [FIG. 4] FIG. 4 is a perspective view of a reflector according to the present embodiment. [FIG. 5] FIG. 5 is a perspective view of the reflector shown in FIG. 4 as viewed from another direction. [FIG. 6] FIG. 6 is a front view of a first reflector. [FIG. 7] FIG. 7 is a front view of the reflector according to the present embodiment. [FIG. 8] FIG. 8 is a side view of the reflector according to the present embodiment. [FIG. 9] FIG. 9 is a top view of a shade according to the present embodiment. [FIG. 10] FIG. 10 is a front view of a second reflector according to the present embodiment. DESCRIPTION OF EMBODIMENTS
[0020] Hereinafter, the present disclosure will be described based on a preferred embodiment with reference to the drawings. The same or equivalent components, members, and processes shown in the drawings are denoted by the same reference numerals, and redundant descriptions thereof will be omitted as appropriate. The embodiment is illustrative rather than limiting the invention, and not all features and combinations thereof described in the embodiment are necessarily essential to the invention.
[0021] FIG. 1 is a side view showing a schematic configuration of a vehicle lamp according to an embodiment of the present invention. FIG. 2 is a perspective view of a main part of a vehicle lamp unit according to the present embodiment. FIG. 3 is an exploded perspective view of the vehicle lamp unit shown in FIG. 2. A vehicle lamp unit 10 shown in FIGS. 2 and 3 is a vehicle headlamp provided in a front portion of a vehicle, and is configured to form both a low-beam light distribution pattern and a high-beam light distribution pattern. FIG. 4 is a perspective view of a reflector according to the present embodiment. FIG. 5 is a perspective view of the reflector shown in FIG. 4 as viewed from another direction.
[0022] A vehicle lamp 100 includes a lamp body 2, an outer lens 4 that covers an opening of the lamp body 2, the vehicle lamp unit 10 provided in a lamp chamber 6 surrounded by the lamp body 2 and the outer lens 4, and an aiming mechanism 8 configured to hold the vehicle lamp unit 10 such that the vehicle lamp unit 10 can be aimed. The vehicle lamp unit 10 includes a projection lens 12 configured to project light emitted from a light source toward a front of the vehicle, a lens holder 14, a reflector 16, a circuit board 20, a heat sink 22, and a fan 24.
[0023] The lens holder 14 includes a substantially cylindrical lens holding portion 14a and three leg portions 14b protruding from the lens holding portion 14a toward a rear side of the vehicle. The projection lens 12 is a transparent member in which a lens main body 12a configured to control an optical path of light emitted from a light source and a flange-shaped attachment portion 12b that protrudes outward from an outer periphery of the lens main body 12a are integrally formed. The projection lens 12 is held by the lens holder 14 by aligning the attachment portion 12b of the projection lens 12 with the lens holding portion 14a of the lens holder 14 and fixing the attachment portion 12b and the lens holding portion 14a with screws 26. The projection lens 12 is manufactured by injection molding using a resin material having high transparency and high heat resistance, such as acrylic or polycarbonate.
[0024] The reflector 16 according to the present embodiment is an optical component in which a part of the reflector 16 is made of a resin material for cost reduction and weight reduction, and the other part is made of a metal material. The reflector 16 includes a first reflector 17 made of a resin material, a shade 18 made of a metal material and assembled to the first reflector 17, and a second reflector 19 made of a metal material and assembled to the first reflector 17.
[0025] FIG. 6 is a front view of the first reflector 17. The first reflector 17 includes a plate-shaped main body 17b in which an opening 17a through which light emitted from a light source passes is formed, side reflection portions 17c provided to protrude forward from both left and right sides of the opening 17a, and an upper reflection portion 17d in which an inner surface of a beam-shaped portion on an upper side of the opening 17a is a reflection surface. In the first reflector 17 according to the present embodiment, the side reflection portions 17c and the upper reflection portion 17d constitute a first reflection portion. Accordingly, of the light emitted from the light source, light passing through the opening 17a toward the side reflection portions 17c can also contribute to the formation of a light distribution pattern.
[0026] FIG. 7 is a front view of the reflector 16 according to the present embodiment. The shade 18 is provided to cross the opening 17a when viewed from the front side of the vehicle, and configured to block a part of the light passing through the opening 17a to form a cut line of a light distribution pattern. The second reflector 19 includes a lower reflection portion 19a provided on a side opposite to the upper reflection portion 17d across the shade 18 to close a part of the opening 17a (a lower part of the opening 17a in FIG. 6) and configured to reflect, toward the front side of the vehicle, a part of the light passing through the opening 17a. Accordingly, since the first reflector 17 is made of a resin material, the overall weight of the reflector 16 can be reduced as compared with a case of a metal member as a whole. On the other hand, the heat resistance can be improved by forming the shade 18 and the second reflector 19 with a metal material.
[0027] FIG. 8 is a side view of the reflector 16 according to the present embodiment. The main body 17b includes first fixing portions 17e to which the shade 18 is assembled and fixed from the first direction D1, and second fixing portions 17f to which the second reflector 19 is assembled and fixed from a second direction D2 different from the first direction D1. The first direction D1 is a direction from a front side to a rear side of the vehicle lamp unit 10. The second direction D2 is a direction from a lower side to an upper side of the vehicle lamp unit 10. The first fixing portions 17e are provided below a pair of side reflection portions 17c in a vehicle up-down direction and on both sides of the opening 17a in a vehicle width direction. Specifically, the first fixing portions 17e are a pair of bosses to be thermally caulked, and each of distal ends thereof is provided downward in the vehicle up-down direction.
[0028] FIG. 9 is a top view of the shade 18 according to the present embodiment. The shade 18 includes a positioning hole 18a positioned with respect to the main body 17b as one of the pair of bosses, which is the first fixing portion 17e, enters, and an elongated hole 18b into which the other of the pair of bosses enters. As a boss is melted in a state in which the bosses are inserted into the holes, the shade 18 is fixed to the first reflector 17 at a predetermined position. Accordingly, even if there is a difference in a thermal expansion coefficient between the first reflector 17 made of the resin material and the shade 18 made of the metal material (for example, aluminum), the shade 18 assembled to the first fixing portion 17e is less likely to be deformed due to the heat. Further, even when sunlight is incident from an outside through the projection lens 12 and condensed in the lamp, the shade 18 formed of the metal member has high heat resistance and is hardly deformed, so that a light distribution pattern with high accuracy can be realized.
[0029] The second fixing portions 17f of the first reflector 17 are provided below the first fixing portions 17e in the vehicle up-down direction and on both sides of the opening 17a in the vehicle width direction. Specifically, the second fixing portions 17f are a pair of bosses to be thermally caulked, and each of distal ends thereof is provided toward the front side in the vehicle front-rear direction.
[0030] FIG. 10 is a front view of the second reflector 19 according to the present embodiment. The second reflector 19 includes a positioning hole 19b positioned with respect to the main body as one of the pair of bosses, which is the first fixing portion 17e, enters, and an elongated hole 19c into which the other of the pair of bosses enters. As a boss is melted in a state in which the bosses are inserted into the holes, the second reflector 19 is fixed to the first reflector 17 at a predetermined position. Accordingly, even when there is a difference in the thermal expansion coefficient between the first reflector 17 made of the resin material and the second reflector 19 made of the metal material, the second reflector 19 assembled to the second fixing portion 17f is less likely to be deformed due to the heat.
[0031] As shown in FIG. 5, the shade 18 is fixed to the first fixing portion 17e in a state in which a rear end 18c in the vehicle front-rear direction extends into the opening 17a. Accordingly, a depth of the shade 18 can be extended even when a tip portion 18d of the shade cannot be made forward due to the restriction of a desired light distribution pattern. Therefore, when the shade 18 is thin (for example, a thickness of the tip portion 18d is 0.6 or more and 1.4 mm or less, and a thickness of the rear end is 0.4 or more and 0.8 mm or less), the overall strength can be ensured. The second reflector 19 is fixed to the second fixing portion 17f in a state in which a rear end 19d in the vehicle front-rear direction extends into the opening 17a.
[0032] The circuit board 20 mainly includes a first light source 20a in which a plurality of light emitting devices 21a for forming a low-beam light distribution pattern are horizontally arranged in a horizontal row, a second light source 20b in which a plurality of light emitting devices 21b for mainly forming a high-beam light distribution pattern are horizontally arranged in a horizontal row, and a drive circuit (not shown) that drives each light emitting device. The second light source 20b is disposed adjacent to the first light source 20a. The first light source 20a is located on an upper side, and the second light source 20b is located on a lower side. In other words, the light emitting devices 21a are arranged above the light emitting devices 21b. In addition, the first light source 20a and the second light source 20b are disposed such that a light emission surface faces the front side of the vehicle.
[0033] The drive circuit is a combination of a passive element such as a capacitor or a coil, an active element such as a transistor or a diode, an IC chip, a memory, and the like, and is mounted in an area of the circuit board below an area where the light sources 20a and 20b are mounted.
[0034] The light emitted from the first light source 20a passes through an upper area between the upper reflection portion 17d and an upper surface 18e of the shade 18 in the opening 17a of the first reflector 17. At this time, a part of the light is reflected by respective reflection surfaces of the side reflection portions 17c, the upper reflection portion 17d, and the upper surface 18e of the shade 18, and is emitted toward the projection lens 12 in a state where the light distribution control is performed. The projection lens 12 is configured to project the light directly arriving from the first light source 20a and the light distributed by the reflection surfaces on the front side of the vehicle in a desired light distribution pattern. Accordingly, on a screen on the front side of the vehicle, an area below a horizontal line is mainly irradiated with the light of the low-beam light distribution pattern.
[0035] The shade 18 is disposed in an area between the light emitting devices 21a and the light emitting devices 21b when the light source is viewed from the front side of the vehicle in a front view. As a result, the shade 18 functions to form a cut line of the low-beam light distribution pattern by blocking a part of the light emitted from the first light source 20a.
[0036] Similarly, the light emitted from the second light source 20b passes between the shade 18 and the second reflector 19. At this time, a part of the light is reflected by a lower surface 18f of the shade 18 and the lower reflection portion 19a of the second reflector 19, and is emitted toward the projection lens 12 in the state in which the light distribution control is performed. The projection lens 12 is configured to project the light directly arriving from the second light source 20b and the light distributed by the reflection surfaces on the front side of the vehicle in a desired light distribution pattern. Accordingly, on a screen on the front side of the vehicle, an area above a horizontal line is mainly irradiated with the light of the high-beam light distribution pattern. In this way, the projection lens 12 projects a light distribution pattern in front of a lamp with the light emitted from at least one of the first light source 20a or the second light source 20b.
[0037] When the light sources described above are driven, heat is generated from the light sources, components constituting a drive circuit, wiring, and the like. A part of the heat generated from the light sources 20a and 20b and the like is transferred to the heat sink 22, and is dissipated to the outside from each part of the heat sink 22, particularly from fins 22a. At this time, cooling air generated by the rotation of the cooling fan 24 flows along the fins 22a, thereby improving heat dissipation. The lens holder 14 is fixed to the heat sink 22 with screws 26. The reflector 16 is fixed to the heat sink 22 by screws 28 with the circuit board 20 interposed therebetween.
[0038] Next, a method for manufacturing the reflector will be described. The manufacturing method according to the present embodiment is a method for manufacturing the reflector 16 including the first reflector 17 made of a resin material, the shade 18 made of a metal material or a ceramic material and assembled to the first reflector 17, and the second reflector 19 made of a metal material or a ceramic material and assembled to the first reflector 17.
[0039] The method includes: a step of preparing the first reflector 17 including the plate-shaped main body 17b in which the opening 17a through which light emitted from a light source passes is formed and the side reflection portions 17c and the upper reflection portion 17d provided around the opening 17a and configured to reflect, toward the front side of the vehicle, a part of light passing through the opening 17a; a first assembling step of assembling the shade 18, which is provided to cross the opening 17a when viewed from the front side of the vehicle and is configured to block a part of light passing through the opening 17a to form a cut line of a light distribution pattern, from a lower side in the vehicle up-down direction to the first fixing portion 17e provided in the main body 17b; and a second assembling step of assembling, from a front side in the vehicle front-rear direction to the second fixing portion 17f provided in the main body 17b, the second reflector 19 including the lower reflection portion 19a provided on a side opposite to the upper reflection portion 17d across the shade 18 to close a part of the opening 17a and configured to reflect, toward the front side of the vehicle, a part of light passing through the opening 17a. Accordingly, as shown in FIG. 8, even when the shade 18 is detached from the first reflector 17, it is possible to prevent the shade 18 from falling downward as it is by the second reflector 19.
[0040] Although the present invention has been described with reference to the above embodiment, the present invention is not limited to the above embodiment, and appropriate combinations and replacements of the configurations of the embodiment are also included in the present invention. Based on the knowledge of those skilled in the art, it is possible to appropriately rearrange the combinations and processing orders in the embodiment, and to make various design changes and other modifications to the embodiment, and embodiments to which such modifications are added are also within the scope of the present invention.
[0041] The present application is based on a Japanese patent application No. 2023-114723 filed on July 12, 2023, the contents of which are incorporated herein by reference.
Claims
1. An optical component comprising: a first reflector made of a resin material; a shade made of a metal material and assembled to the first reflector; and a second reflector made of a metal material and assembled to the first reflector, wherein the first reflector includes: a main body that is plate-shaped and in which an opening through which light emitted from a light source passes is formed; and a first reflection portion provided around the opening and configured to reflect, toward a front side of a vehicle, a part of light passing through the opening, the shade is provided to cross the opening when viewed from the front side of the vehicle, and configured to block a part of light passing through the opening to form a cut line of a light distribution pattern, the second reflector includes a second reflection portion provided on a side opposite to the first reflection portion across the shade to close a part of the opening, and configured to reflect, toward the front side of the vehicle, a part of light passing through the opening, and the main body includes: a first fixing portion to which the shade is assembled and fixed from a first direction; and a second fixing portion to which the second reflector is assembled and fixed from a second direction different from the first direction.
2. The optical component according to claim 1, wherein the first fixing portion is a pair of bosses to be thermally caulked, and the shade includes: a positioning hole configured to be positioned with respect to the main body as one of the pair of bosses enters into the positioning hole; and an elongated hole into which the other of the pair of bosses enters.
3. The optical component according to claim 1 or 2, wherein the second fixing portion is provided below the first fixing portion in a vehicle up-down direction and on both sides of the opening in a vehicle width direction.
4. The optical component according to any one of claims 1 to 3, wherein the second fixing portion is a pair of bosses to be thermally caulked, and the second reflector includes: a positioning hole configured to be positioned with respect to the main body as one of the pair of bosses enters into the positioning hole; and an elongated hole into which the other of the pair of bosses enters.
5. The optical component according to any one of claims 1 to 4, wherein the shade is fixed to the first fixing portion in a state where a rear end of the shade in a vehicle front-rear direction extends into the opening.
6. The optical component according to any one of claims 1 to 5, wherein the second reflector is fixed to the second fixing portion in a state where a rear end of the second reflector in a vehicle front-rear direction extends into the opening.
7. A vehicle lamp comprising: a light source in which a plurality of light emitting devices are disposed; the optical component according to any one of claims 1 to 6; and a projection lens configured to project, toward a front side of a vehicle, light emitted from the light source and passed through the opening of the optical component, wherein the optical component is configured to: form a first light distribution pattern by light passing between the first reflector and the shade; and form a second light distribution pattern by light passing between the shade and the second reflector.
8. A method for manufacturing an optical component, the optical component including a first reflector made of a resin material, a shade made of a metal material and assembled to the first reflector, and a second reflector made of a metal material and assembled to the first reflector, the method comprising: a step of preparing the first reflector including: a main body that is plate-shaped and in which an opening through which light emitted from a light source passes is formed; and a first reflection portion provided around the opening and configured to reflect, toward a front side of a vehicle, a part of light passing through the opening; a first assembling step of assembling the shade to a first fixing portion provided in the main body from a lower side in a vehicle up-down direction, the shade being provided to cross the opening when viewed from the front side of the vehicle and configured to block a part of light passing through the opening to form a cut line of a light distribution pattern; and a second assembling step of assembling a second reflector to a second fixing portion provided in the main body from a front side in a vehicle front-rear direction, the second reflector including a second reflection portion provided on a side opposite to the first reflection portion across the shade to close a part of the opening and being configured to reflect, toward the front side of the vehicle, a part of light passing through the opening.