Vehicular headlight

Abstract

To provide a lightweight vehicular headlight while reducing the number of components.SOLUTION: A vehicular headlight comprises a housing, a lamp unit comprising a light source and a reflector, a bracket supporting the lamp unit, and an aiming element for displacing the bracket with respect to the housing. The bracket and the reflector are constituted as a single component made of a thermoplastic resin.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present disclosure relates to a vehicle headlamp.

Background Art

[0002] Patent Document 1 discloses a vehicle headlamp in which a reflector and a mounting portion to which an aiming element is attached are configured as a single component.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, further weight reduction is required for vehicle headlamps.

[0005] An object of the present disclosure is to suppress an increase in the number of parts and an increase in weight in a vehicle headlamp.

Means for Solving the Problems

[0006] A vehicle headlamp according to one aspect of the present disclosure is a vehicle headlamp that irradiates light forward of a vehicle, including a housing, a lamp unit having a light source and a reflector, a bracket that supports the lamp unit, and an aiming element that displaces the bracket with respect to the housing, wherein the bracket and the reflector are formed of a single component made of a thermoplastic resin.

Effects of the Invention

[0007] According to the present disclosure, it is possible to suppress an increase in the number of parts and an increase in weight in a vehicle headlamp.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Embodiments for Carrying Out the Invention

[0009] Hereinafter, embodiments of the present invention will be described with reference to the drawings. The dimensions of each member shown in the drawings may be different from the actual dimensions of each member for convenience of explanation. Also, in the drawings, arrow U indicates the upward direction of the illustrated structure. Arrow D indicates the downward direction of the illustrated structure. Arrow F indicates the forward direction of the illustrated structure. Arrow B indicates the backward direction of the illustrated structure. Arrow R indicates the rightward direction of the illustrated structure. Arrow L indicates the leftward direction of the illustrated structure. These directions are relative directions set for the vehicle headlamp 1 shown in FIG. 1, and the direction of light emitted from the vehicle headlamp 1 is taken as the forward direction.

[0010] FIG. 1 is a front view illustrating the configuration of the vehicle headlamp 1 according to the present embodiment. FIG. 2 is an end view showing the configuration as seen from the arrow direction of the cross section taken along line II-II in FIG. 1. FIG. 3 is an end view showing the configuration as seen from the arrow direction of the cross section taken along line III-III in FIG. 1. FIG. 4 is an end view showing the configuration as seen from the arrow direction of the cross section taken along line IV-IV in FIG. 1.

[0011] The vehicle headlamp 1 is configured to be provided on a vehicle and irradiate light forward of the vehicle. The vehicle headlamp 1 is mounted on, for example, a motorcycle.

[0012] As illustrated in FIGS. 2 and 3, the vehicle headlamp 1 includes a housing 2 and a cover 3. The housing 2 has a recess opened forward. The cover 3 closes the opening of the housing 2. A lamp chamber 4 is formed by the housing 2 and the cover 3.

[0013] As illustrated in FIGS. 1 and 4, the vehicle headlamp 1 includes a first lamp unit 5. The first lamp unit 5 is, for example, a lamp unit that forms a high beam. As illustrated in FIG. 4, the first lamp unit 5 has a first light source 51 and a first reflector 52. The first light source 51 is configured to emit light toward the first reflector 52. The first light source 51 is constituted by, for example, an LED (Light Emitting Diode) element. The first reflector 52 is disposed below the first light source 51. The first reflector 52 is configured to reflect the light emitted from the first light source 51 forward. In this example, as illustrated in FIG. 3, the first reflector 52 has two reflecting surfaces 52A that reflect the light emitted from two first light sources 51 (not shown) disposed apart from each other left and right.

[0014] As illustrated in FIGS. 2 to 4, the vehicle headlamp 1 includes a bracket 6. The bracket 6 is configured to support the first lamp unit 5. Specifically, as shown in FIG. 4, the first lamp unit 5 has a wiring board 53 and a heat sink 54. A first light source 51 is mounted on the wiring board 53. The wiring board 53 is attached to the heat sink 54 by a screw member. The bracket 6 has a first light source mounting portion 61 provided above the first reflector 52. The heat sink 54 is attached to the first light source mounting portion 61 of the bracket 6 by a screw member (not shown) with the first light source 51 facing the lower first reflector 52.

[0015] The first reflector 52 of the first lamp unit 5 and the bracket 6 are formed of a single part made of a thermoplastic resin. The thermoplastic resin is, for example, a resin mainly composed of a polycarbonate resin. The single part is formed, for example, only of the polycarbonate resin.

[0016] The expression "single part" used in this specification is intended to mean that the bracket and the reflector have a monolithic structure made of a thermoplastic resin, and preferably, they are a one-piece molded product formed by integral molding of the thermoplastic resin. Also, a structure in which the bracket and the reflector are manufactured as individual parts and are joined by means such as fitting, adhesion, or screwing is not called a single part.

[0017] The reflecting surface 52A of the first reflector 52 is formed, for example, by performing metal vapor deposition on the surface of the portion that becomes the first reflector 52 in a single part made of a thermoplastic resin.

[0018] According to such a configuration, since the bracket 6 and the first reflector 52 are configured as a single component, an increase in the number of parts and an increase in the assembly man-hours can be suppressed. Thereby, an increase in the manufacturing cost of the vehicle headlamp 1 can be suppressed. Further, since the single component is formed of a thermoplastic resin, weight reduction can be achieved as compared with the case where it is formed of a bulk molding compound (BMC) or the like used as a material for conventional brackets.

[0019] As illustrated in FIGS. 2 and 3, the vehicle headlamp 1 includes an aiming element 7. The aiming element 7 is configured to displace the bracket 6 with respect to the housing 2. In this example, the aiming element 7 is configured to support the bracket 6 in a state where it can swing in the vertical and horizontal directions with respect to the housing 2.

[0020] Specifically, as illustrated in FIG. 2, the aiming element 7 has a first nut member 71, a first aiming screw 72, a pivot shaft 73, and a receiving portion 74. The first nut member 71 is attached to the bracket 6. Specifically, the bracket 6 has a first attachment portion 62 in which a first attachment hole 62A is formed. Although not shown in FIG. 2, the first nut member 71 is inserted and attached into the first attachment hole 62A of the first attachment portion 62.

[0021] The first aiming screw 72 is configured to displace the first nut member 71. Specifically, the rear end portion of the first aiming screw 72 is supported by the housing 2, and the front end portion of the first aiming screw 72 is configured to engage with the first nut member 71. By rotating the rear end portion of the first aiming screw 72, the first nut member 71 moves back and forth with respect to the housing 2.

[0022] The pivot shaft 73 and the receiving portion 74 are configured to rotatably support the bracket 6 to which the first nut member 71 is attached with respect to the housing 2. Specifically, the rear end portion of the pivot shaft 73 is supported by the housing 2, and the front end portion of the pivot shaft 73 is formed in a spherical shape. The receiving portion 74 is configured such that the spherical front end portion of the pivot shaft 73 is swingably connected thereto. The receiving portion 74 is attached to the bracket 6. Specifically, the bracket 6 has a support portion attachment portion 63. The receiving portion 74 is attached to the support portion attachment portion 63 by a screw member.

[0023] The pivot shaft 73 and the receiving portion 74 are located below the first nut member 71 and the first aiming screw 72. The bracket 6 to which the first nut member 71 is attached is supported in a state of being swingable in the vertical direction with respect to the housing 2 with the spherical front end portion of the pivot shaft 73 as a fulcrum. When the first aiming screw 72 is rotated, the bracket 6 swings in the vertical direction with respect to the housing 2 with the spherical front end portion of the pivot shaft 73 as a fulcrum. Thereby, the vertical optical axis adjustment of the first lamp unit 5 is performed. The first nut member 71 is an example of a first movable portion. The first aiming screw 72 is an example of a first driving portion. The pivot shaft 73 and the receiving portion 74 are an example of a support portion.

[0024] Also, as illustrated in FIG. 3, the aiming element 7 has a second nut member 75 and a second aiming screw 76. The second nut member 75 is attached to the bracket 6. Specifically, the bracket 6 has a second attachment portion 64 in which a second attachment hole 64A is formed. Although not shown in FIG. 3, the second nut member 75 is inserted and attached to the second attachment hole 64A of the second attachment portion 64.

[0025] The second aiming screw 76 is configured to displace the second nut member 75. Specifically, the rear end portion of the second aiming screw 76 is supported by the housing 2, and the front end portion of the second aiming screw 76 is configured to engage with the second nut member 75. By rotating the rear end portion of the second aiming screw 76, the second nut member 75 moves back and forth with respect to the housing 2.

[0026] The second nut member 75 and the second aiming screw 76 are located to the left of the pivot shaft 73 and the receiving portion 74. The bracket 6 to which the second nut member 75 is attached is supported in a state where it can swing in the left - right direction with respect to the housing 2 with the spherical front end portion of the pivot shaft 73 as a fulcrum. When the second aiming screw 76 is rotated, the bracket 6 swings in the left - right direction with respect to the housing 2 with the spherical front end portion of the pivot shaft 73 as a fulcrum. Thereby, the adjustment of the optical axis in the left - right direction of the first lamp unit 5 is performed. The second nut member 75 is an example of a second movable part. The second aiming screw 76 is an example of a second driving part.

[0027] FIG. 5 is a front view illustrating the configuration of the bracket 6. As illustrated in FIG. 5, the first attachment portion 62, the support portion attachment portion 63, and the second attachment portion 64 of the bracket 6 are provided at positions different from those of the first reflector 52 in a front view. The receiving portion 74 attached to the support portion attachment portion 63 and the pivot shaft 73 connected to the receiving portion 74 are also provided at positions different from those of the first reflector 52 in a front view. In this example, the first attachment portion 62 is disposed above and to the right of the first reflector 52. The support portion attachment portion 63 is disposed to the right of the first reflector 52. The second attachment portion 64 is disposed to the left of the first reflector 52.

[0028] When molding a single part with a thermoplastic resin, the thermoplastic resin is heated and then filled into a mold, and after cooling, the single part is taken out. For this reason, in the thick-walled portion of the single part, dimensional changes and bending are likely to occur before and after cooling. Therefore, it is preferable to form the first reflector 52 and its periphery, which particularly require high dimensional accuracy, as thin as possible.

[0029] As described above, in the bracket 6, the first mounting portion 62, the support portion mounting portion 63, and the second mounting portion 64 are located at positions that do not overlap the first reflector 52 in a front view. The expression "position in a front view" used here is the position seen from the direction facing the reflecting surface 52A of the first reflector 52. In this example, the "position in a front view" is the position where the bracket 6 is viewed from the front. As a result, since the first mounting portion 62, the support portion mounting portion 63, and the second mounting portion 64 do not exist behind the first reflector 52, the thickness of the first reflector 52 in the front-rear direction does not increase, and warping of the first reflector 52 due to resin molding can be suppressed.

[0030] As illustrated in FIG. 1, the vehicle headlamp 1 includes a second lamp unit 8 and a third lamp unit 9.

[0031] The second lamp unit 8 is, for example, a lamp unit that forms a low beam. As illustrated in FIG. 2, the second lamp unit 8 includes a second light source 81, a second reflector 82, and a second light source mounting portion 83. The second light source 81 is configured to emit light toward the second reflector 82. The second light source 81 is, for example, constituted by an LED (Light Emitting Diode) element. The second reflector 82 is disposed below the second light source 81. The second reflector 82 is configured to reflect the light emitted from the second light source 81 forward.

[0032] The second light source mounting portion 83 is provided above the second reflector 82. The second light source 81 is mounted on the second light source mounting portion 83. Specifically, the second lamp unit 8 has a wiring board 84 and a heat sink 85. The second light source 81 is mounted on the wiring board 84. The wiring board 84 is attached to the heat sink 85 by a screw member. The heat sink 85 is attached to the second light source mounting portion 83 by a screw member (not shown) with the second light source 81 facing the second reflector 82 below.

[0033] The second lamp unit 8 is supported by the bracket 6. Specifically, as illustrated in FIG. 5, the bracket 6 has a third mounting portion 65. The second lamp unit 8 is attached to the third mounting portion 65. The third mounting portion 65 has a through hole 65A and a rib portion 65B. The rib portion 65B is formed around the through hole 65A. In this example, the third mounting portion 65 has a first through hole 65A1, a second through hole 65A2, and a third through hole 65A3, and a first rib portion 65B1, a second rib portion 65B2, and a third rib portion 65B3.

[0034] FIG. 6 illustrates a configuration as viewed in the direction of the arrow of a cross section taken along line VI-VI in FIG. 1. As illustrated in FIG. 6, the second lamp unit 8 has a boss portion 86 having a screw hole 86A. The boss portion 86 is configured to extend from behind the second reflector 82 of the second lamp unit 8. The second lamp unit 8 is disposed on the third mounting portion 65 of the bracket 6 such that the screw hole 86A of the boss portion 86 communicates with the through hole 65A of the bracket 6, and is attached to the third mounting portion 65 by screwing a screw member 87 passing through the through hole 65A into the screw hole 86A of the boss portion 86. The periphery of the boss portion 86 of the second lamp unit 8 is reinforced by the rib portion 65B of the third mounting portion 65.

[0035] The third lamp unit 9 is, for example, a lamp unit that forms a low beam. The third lamp unit 9 has a light source, a reflector, a light source mounting portion, etc., similar to the second lamp unit 8. The third lamp unit 9 is supported by the bracket 6. As illustrated in FIG. 5, the bracket 6 has a fourth mounting portion 66 to which the third lamp unit 9 is attached. The fourth mounting portion 66 has a through hole and a rib portion, similar to the third mounting portion 65. Note that since the configuration of the third lamp unit 9 and the assembling structure of the third lamp unit 9 and the fourth mounting portion 66 are the same as those of the second lamp unit 8 and the assembling structure of the second lamp unit 8 and the third mounting portion 65, except that they are symmetric, a detailed description thereof is omitted.

[0036] According to such a configuration, the third mounting portion 65 of the second lamp unit 8 and the fourth mounting portion 66 of the third lamp unit 9 are also configured as part of the bracket 6. In other words, the bracket 6 that supports the first lamp unit 5, the third mounting portion 65 of the second lamp unit 8, and the fourth mounting portion 66 of the third lamp unit 9 are configured as a single component. Therefore, an increase in the number of parts and an increase in the assembly man-hours can be suppressed. Also, alignment between the first lamp unit 5 and the second lamp unit 8 and the third lamp unit 9 becomes unnecessary.

[0037] In the above embodiment, the bracket 6 is supported by the housing 2 in a state where it can swing in the vertical and horizontal directions. However, the bracket 6 may be configured to be supported by the housing 2 in a state where it can swing only in the vertical direction, for example.

[0038] FIG. 7 illustrates the configuration of a bracket 16 according to a modification. FIG. 8 shows the configuration as viewed from the arrow direction of a cross section taken along line VIII-VIII in FIG. 7. In FIG. 7, the same components as those of the bracket 6 shown in FIG. 5 are denoted by the same reference numerals. In FIG. 8, the housing 2, which is a member different from the bracket 16, is represented by a dashed line.

[0039] The bracket 16 according to the modification example is configured to be supported so as to be swingable only in the vertical direction with respect to the housing 2. Specifically, as illustrated in FIG. 7, the bracket 16 has a first attachment portion 62 to which a first nut member 71 (see FIG. 2) is attached. The bracket 16 does not have a second attachment portion 64 (see FIG. 5) to which a second nut member 75 is attached.

[0040] Instead of the support portion attachment portion 63 (see FIG. 5), the bracket 16 has a rotation shaft 67. The rotation shaft 67 extends in the left - right direction at the lower part of the bracket 16. The rotation shaft 67 is in a position that does not overlap the first reflector 52 in a front view.

[0041] As illustrated in FIG. 8, a receiving portion 21 to which the rotation shaft 67 is rotatably connected is formed in the housing 2. The bracket 16 to which the first nut member 71 (see FIG. 2) is attached is supported in a state swingable in the vertical direction with respect to the housing 2 with the rotation shaft 67 as a support shaft. When the first aiming screw 72 (see FIG. 2) is rotated, the bracket 16 swings in the vertical direction with respect to the housing 2 with the rotation shaft 67 as a support shaft. Thereby, the vertical optical axis adjustment of the first lamp unit 5 is performed. The rotation shaft 67 is an example of a support portion.

[0042] Regarding other configurations of the bracket 16, since they are the same as those of the bracket 6 shown in FIG. 5, detailed description thereof is omitted.

[0043] Even in such a configuration, since the first attachment portion 62 and the rotation shaft 67 do not exist behind the first reflector 52, the thickness of the first reflector 52 in the front - rear direction does not increase, and warping of the first reflector 52 due to resin molding can be suppressed.

[0044] As described above, embodiments of the present invention have been explained. Needless to say, the technical scope of the present invention should not be construed in a limited manner by the description of the embodiments. These embodiments are merely examples, and those skilled in the art will understand that various modifications of the embodiments are possible within the scope of the invention described in the claims. The technical scope of the present invention should be determined based on the scope of the invention described in the claims and its equivalent scope.

[0045] In the above embodiment, as a structure for supporting the bracket 6 in a state where it can swing in the vertical direction with respect to the housing 2, a first nut member 71 and a first aiming screw 72 are arranged with respect to the upper part of the bracket 6, and a pivot shaft 73 and a receiving portion 74 are arranged with respect to the lower part of the bracket 6. However, a pivot shaft 73 and a receiving portion 74 may be arranged with respect to the upper part of the bracket 6, and a first nut member 71 and a first aiming screw 72 may be arranged with respect to the lower part of the bracket 6. In this case, a support portion mounting portion 63 is formed in the upper part of the bracket 6, and a first mounting portion 62 is formed in the lower part of the bracket 6.

[0046] In the above modification, as a structure for supporting the bracket 16 in a state where it can swing in the vertical direction with respect to the housing 2, a first nut member 71 and a first aiming screw 72 are arranged with respect to the upper part of the bracket 16, and a rotation shaft 67 is formed in the lower part of the bracket 16. However, a rotation shaft 67 may be formed in the upper part of the bracket 16, and a first nut member 71 and a first aiming screw 72 may be arranged with respect to the lower part of the bracket 16. In this case, a first mounting portion 62 is formed in the lower part of the bracket 6.

[0047] In the above-described embodiments and modifications, the first lamp unit 5 may be configured as a lamp unit having a function different from that of the lamp unit forming the high beam or a lamp unit having an additional function different from that of the lamp unit forming the high beam. The second lamp unit 8 and the third lamp unit 9 may be configured as a lamp unit having a function different from that of the lamp unit forming the low beam or a lamp unit having an additional function different from that of the lamp unit forming the low beam.

[0048] In the above-described embodiments and modifications, the second lamp unit 8 and the third lamp unit 9 are attached to the bracket 6 and the bracket 16. However, only one of the second lamp unit 8 and the third lamp unit 9 may be attached to the bracket 6 and the bracket 16, or an additional lamp unit may be attached in addition to the second lamp unit 8 and the third lamp unit 9.

Explanation of Reference Numerals

[0049] 1 Vehicle headlamp 2 Housing 3 Cover 4 Lamp chamber 5 First lamp unit 6 Bracket 7 Aiming element 8 Second lamp unit 9 Third lamp unit 16 Bracket 21 Receiving portion 51 First light source 52 First reflector 52A Reflective surface 53 Wiring board 54 Heat sink 61 First light source mounting portion 62 First mounting portion 62A First mounting hole 63 Support portion mounting portion 64 Second mounting portion 64A Second mounting hole 65 Third mounting portion 65A Through hole 65A1 First through-hole 65A2 Second through-hole 65A3 Third through-hole 65B Rib portion 65B1 First rib portion 65B2 Second rib portion 65B3 Third rib portion 66 Fourth mounting portion 67 Rotation shaft 71 First nut member 72 First aiming screw 73 Pivot shaft 74 Receiving portion 75 Second nut member 76 Second aiming screw 81 Second light source 82 Second reflector 83 Second light source mounting portion 84 Wiring board 85 Heat sink 86 Boss portion 86A Threaded hole 87 Threaded member

Claims

1. A vehicle headlamp that irradiates light in front of a vehicle, comprising: a housing; a lamp unit having a light source and a reflector; a bracket that supports the lamp unit; an aiming element that displaces the bracket with respect to the housing; and a vehicle headlamp, wherein the bracket and the reflector are formed of a single part made of a thermoplastic resin.

2. The aiming element includes: a first movable part that displaces with respect to the housing together with the lamp unit; a first driving part that displaces the first movable part; and a support part that rotatably supports the first movable part with respect to the housing. The bracket has: a first attachment part to which the first movable part is attached; The vehicle headlamp according to claim 1, wherein the first attachment part and the support part are provided at positions different from the reflector in a front view.

3. The aiming element includes: a second movable part that displaces with respect to the housing together with the lamp unit; a second driving part that displaces the second movable part. The bracket has: a second attachment part to which the second movable part is attached; The vehicle headlamp according to claim 1 or 2, wherein the second attachment part is provided at a position different from the reflector in a front view.

4. A second lamp unit is provided, The vehicle headlamp according to claim 1 or 2, wherein the bracket has a third attachment part to which the second lamp unit is attached.

5. The second lamp unit has a boss part having a screw hole, The vehicle headlamp according to claim 4, wherein the second lamp unit is attached to the third attachment part by screwing a screw member that passes through a through hole provided in the third attachment part into the boss part.

6. The vehicle headlamp according to claim 1 or 2, wherein the thermoplastic resin is mainly composed of a polycarbonate resin.

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