Vehicle lamp

Abstract

To provide a vehicle lamp capable of illuminating a wide range of positions in a horizontal direction using a projection lens whose incident surface and emission surface are a single curved surface.SOLUTION: A vehicle lamp 10 comprises: a light guide lens 12 that guides light from a plurality of light sources 21 arranged in a width direction; and a projection lens 13 that projects the light guided by the light guide lens 12 to form a projection light distribution pattern (light distribution pattern LP for low beam) that illuminates the front of a vehicle. The light guide lens 12 has a lateral reflection part 40 that partially protrudes toward the projection lens 13, and the lateral reflection part 40 reflects at least a portion of the light from an end light source 21E located at the end of the plurality of light sources 21 toward a projection incidence surface 13a of the projection lens 13 in a lateral illumination direction Ds so as to travel toward a horizontal end part of the projection light distribution pattern.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present disclosure relates to vehicle lamps.

Background Art

[0002] In vehicle lamps, there is a consideration of projecting light from a light source with a projection lens to irradiate a wide range of positions in the horizontal direction (see, for example, Patent Document 1). In this vehicle lamp, by adopting a configuration in which a plurality of lens parts having different optical characteristics are connected in the width direction, a wide range of positions in the horizontal direction are irradiated.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the above vehicle lamp, the configuration of the projection lens becomes complicated, leading to an increase in manufacturing cost. For this reason, it is conceivable that the vehicle lamp uses a projection lens composed of an incident surface and an exit surface that are a single curved surface to avoid complication and suppress an increase in manufacturing cost. However, it becomes difficult to irradiate a wide range of positions in the horizontal direction.

[0005] The present disclosure has been made in view of the above circumstances, and an object thereof is to provide a vehicle lamp that can irradiate a wide range of positions in the horizontal direction by using a projection lens in which an incident surface and an exit surface are a single curved surface.

Means for Solving the Problems

[0006] The vehicle lamp of the present disclosure includes a light guide lens that guides light from a plurality of light sources arranged in the width direction, and a projection lens that projects the light guided by the light guide lens to form a projection light distribution pattern that irradiates the front of the vehicle. The light guide lens has a side reflection portion that partially protrudes toward the projection lens side, and the side reflection portion reflects at least a part of the light from an end light source located at an end of the plurality of light sources toward the projection incident surface of the projection lens in a side irradiation direction inclined with respect to the optical axis direction so as to travel to a horizontal end portion in the projection light distribution pattern.

Effect of the Invention

[0007] According to the vehicle lamp of the present disclosure, a wide range of positions in the horizontal direction can be irradiated using a projection lens in which the incident surface and the exit surface are a single curved surface.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

Figure 16

Embodiments for Carrying Out the Invention

[0009] Hereinafter, each embodiment of the vehicle lamp according to the present disclosure will be described with reference to the drawings. In FIGS. 2 to 4 and FIGS. 10 to 12, the light source unit 11 is omitted for easy understanding of each configuration.

Example

[0010] Example 1 of the vehicle lamp 10 according to an embodiment of the vehicle lamp according to the present disclosure will be described with reference to FIGS. 1 to 8. The vehicle lamp 10 of Example 1 is used as a headlamp device for vehicles such as automobiles. This vehicle lamp 10 is provided in a lamp chamber formed by a lamp housing whose open front end is covered with an outer lens on both the left and right sides at the front of the vehicle. The vehicle lamp 10 is provided in the lamp chamber via a vertical optical axis adjustment mechanism and a horizontal optical axis adjustment mechanism, and appropriately irradiates the front of the vehicle. In the following description, in the vehicle lamp 10, the direction in which the vehicle travels is defined as the front-rear direction (referred to as Z in the drawings), the vertical direction when the front-rear direction is along the horizontal plane is defined as the up-down direction (referred to as Y in the drawings), and the direction orthogonal to the front-rear direction and the up-down direction (horizontal direction) is defined as the width direction (referred to as X in the drawings). In each of these directions, the front and rear in the front-rear direction, the upper and lower in the up-down direction, and the left and right in the width direction, as viewed from the passengers in the vehicle, are used. Here, since the vehicle lamp 10 of Example 1 has basically the same configuration whether it is provided on the left side or the right side of the vehicle and is inverted in the width direction, hereinafter, the vehicle lamp 10 provided on the right side will be used for the description.

[0011] As shown in FIGS. 1 to 5, the vehicle lamp 10 of Example 1 includes a light source unit 11, a light guide lens 12, and a projection lens 13, and constitutes a lamp unit in which the projection optical axis Lp is along the front-rear direction. This light source unit 11 is attached to, for example, a heat sink formed of an aluminum plate, an aluminum die-cast, or a resin having thermal conductivity. This heat sink can be configured to release the heat generated by the light source unit 11 mainly from each heat dissipation fin to the outside, for example, by providing a plurality of heat dissipation fins. Further, the heat sink may be configured as a mounting member to which the light guide lens 12 and the projection lens 13 are attached via a support member or the like.

[0012] As shown in FIG. 1 and the like, the light source unit 11 includes five light sources 21 and a substrate 22 on which they are mounted. Each of these light sources 21 is composed of a light-emitting element such as an LED (Light Emitting Diode). Five light sources 21 are arranged in substantially equal intervals in the width direction. When individually indicating these five light sources 21, from the left side when viewing FIG. 1 from the front, they are the first light source 211, the second light source 212, the third light source 213, the fourth light source 214, and the fifth light source 215. In the first embodiment, the first light source 211 at the left end of each light source 21 is the end light source 21E. At least a part of the light emitted by this end light source 21E is used for forming a side irradiation pattern Ps (see FIG. 7 and the like) described later.

[0013] The substrate 22 is in the shape of a plate formed of an aluminum substrate. Note that the substrate 22 may be formed of a resin material such as a glass epoxy substrate or may be formed of other materials. The substrate 22 is provided with wiring patterns and connector terminals for electrically connecting the five light sources 21. This substrate 22 appropriately supplies power from a lighting control circuit via the connector terminals to appropriately light each light source 21.

[0014] As shown in FIGS. 1 to 5, the light guide lens 12 is provided corresponding to the five light sources 21 of the light source unit 11 and is a molded product made of a transparent resin material. This light guide lens 12 guides the light emitted from each light source 21 inward and is an optical lens that forms a projection light distribution pattern (the passing light distribution pattern LP (see FIG. 8) described later) in cooperation with the projection lens 13. Five light guide incident portions 31 are provided on the lower side in the vertical direction of the light guide lens 12. Each light guide incident portion 31 corresponds individually to each light source 21 and has optical characteristics (such as the shape of the surface) corresponding to the required light distribution images for each while having basically the same configuration as each other.

[0015] Each light guide incident part 31 has a portion facing the corresponding light source 21 protruding toward the light source 21 side, and its center is recessed toward the side opposite to the light source 21. As shown in FIG. 4, it has a facing incident surface 32, an inclined incident surface 33, and an annular reflection surface 34. The facing incident surface 32 is convexly curved toward the light source 21 side, and the light source 21 is positioned near the focus on the rear side (light source 21 side) (rear side focus). The facing incident surface 32 makes the light emitted from the light source 21 enter the light guide lens 12 as parallel light traveling substantially parallel to the axis of the light guide incident part 31, and makes it travel toward the lower internal reflection surface 35 described later. Note that this parallel light (parallel light) refers to light in a collimated state after passing through the facing incident surface 32.

[0016] The inclined incident surface 33 is provided so as to surround the facing incident surface 32 in a frustum of a cone shape while protruding from the facing incident surface 32 toward the light source 21 side. This inclined incident surface 33 makes the light from the light source 21 that does not travel toward the facing incident surface 32 enter the light guide lens 12. The annular reflection surface 34 is provided so as to surround the inclined incident surface 33 in a frustum of a cone shape, and is the position where the light incident from the inclined incident surface 33 into the light guide lens 12 travels. The annular reflection surface 34 reflects the light incident from the inclined incident surface 33, and makes it travel toward the lower internal reflection surface 35 described later as parallel light traveling substantially parallel to the axis of the light guide incident part 31. Note that the annular reflection surface 34 may reflect light using total reflection, or may reflect light by adhering aluminum, silver, etc. by vapor deposition, painting, or the like.

[0017] The lower inner reflecting surface 35 is provided on the front side in the front-rear direction of each light guide incident portion 31. This lower inner reflecting surface 35 reflects the light incident from each light guide incident portion 31 toward the upper inner reflecting surface 36 of the light guide lens 12. The lower inner reflecting surface 35 is configured by providing a plurality of free-form surfaces based on a paraboloid with the vicinity of the cut-off edge portion 36a of the upper inner reflecting surface 36 as the focus. The lower inner reflecting surface 35 reflects the light incident from the light guide incident portion 31, causing the light to travel toward the vicinity of the cut-off edge portion 36a. For this reason, the lower inner reflecting surface 35 functions as a first inner reflecting surface that reflects the light incident from the light guide incident portion 31 in a crossing direction that crosses the optical axis direction along the projection optical axis Lp. Note that the lower inner reflecting surface 35 may use total reflection, perform a reflection process, or have other configurations as long as it reflects as described above. Also, the lower inner reflecting surface 35 may be a single surface and is not limited to the configuration of the first embodiment.

[0018] As shown in FIG. 3, in the lower inner reflecting surface 35 of the first embodiment, the portion corresponding to the end light source 21E located on the leftmost side among the light sources 21 is the end reflecting surface portion 35E. This end reflecting surface portion 35E has three reflecting curved surfaces 35e, which are the reflecting curved surface 35ea, the reflecting curved surface 35eb, and the reflecting curved surface 35ec in order from the left in the width direction. The reflecting curved surface 35eb and the reflecting curved surface 35ec are optically set to reflect the light from the light guide incident portion 31 toward the vicinity of the cut-off edge portion 36a. And the reflecting curved surface 35ea is optically set to reflect the light from the light guide incident portion 31 in the direction of traveling to the laterally reflecting portion 40 (its laterally reflecting surface 41) described later, and in the first embodiment, it is reflected upward along the vertical direction. For this reason, the end reflecting surface portion 35E reflects a part of the light that has traveled to the reflecting curved surface 35ea among the light from the end light source 21E toward the upper inner reflecting surface 36 in the direction toward the laterally reflecting portion 40, and reflects the remaining light toward the vicinity of the cut-off edge portion 36a in the same manner as the other lower inner reflecting surfaces 35.

[0019] The upper inner reflecting surface 36 is provided above the lower inner reflecting surface 35 in the vertical direction. This upper inner reflecting surface 36 reflects the light reflected by the lower inner reflecting surface 35 toward the light guiding and emitting portion 37 of the light guiding lens 12. Therefore, the upper inner reflecting surface 36 functions as a second inner reflecting surface that reflects the light reflected by the lower inner reflecting surface 35 in the optical axis direction along the projection optical axis Lp. At this upper inner reflecting surface 36, the lower edge portion is a cut-off edge portion 36a. This cut-off edge portion 36a forms a cut-off line CL and has a shape in which horizontal edges with different heights are joined by inclined edges. This cut-off edge portion 36a is located near the focal point (rear focal point) of the projection lens 13 that passes through the light guiding and emitting portion 37 (emitting surface 38) described later. Since the upper inner reflecting surface 36 does not reflect the light that has been reflected by the lower inner reflecting surface 35 and has traveled downward beyond the cut-off edge portion 36a toward the light guiding and emitting portion 37, the shape of the cut-off edge portion 36a can be reflected in the light reflected toward the light guiding and emitting portion 37. Further, the upper inner reflecting surface 36 reflects the light reflected by the reflecting curved surface 35ea of the end reflecting surface portion 35E of the lower inner reflecting surface 35 forward along the front-rear direction.

[0020] Here, even when the vehicle lamp 10 is provided on the left side of the vehicle, the relationship between the direction of inclination and the height at the cut-off edge portion 36a of the upper inner reflecting surface 36 is not inverted in the width direction. That is, although the vehicle lamp 10 is inverted in the width direction between the right side and the left side of the vehicle, the inclinations of the cut-off edge portions 36a of the upper inner reflecting surface 36 are in the same direction as each other.

[0021] The light guiding and emitting portion 37 is provided in front of the upper inner reflecting surface 36 in the front-rear direction. This light guiding and emitting portion 37 protrudes partially forward in the light guiding lens 12, and the protruding end is the emitting surface 38. The emitting surface 38 has a positional relationship facing the upper inner reflecting surface 36 in the front-rear direction, and is a free-form surface based on a spherical surface set such that the focal point (rear focal point) of the projection lens 13 is near the cut-off edge portion 36a of the upper inner reflecting surface 36. The emitting surface 38 emits the light reflected by the upper inner reflecting surface 36 forward in the front-rear direction.

[0022] In this light guide emission unit 37, a side reflection unit 40 is provided at the left end. The side reflection unit 40 emits the light that has been reflected by the reflection curved surface 35ea of the end reflection surface portion 35E of the lower inner reflection surface 35 and then reflected by the upper inner reflection surface 36 in the lateral irradiation direction Ds that is inclined to the right in the width direction with respect to the projection optical axis Lp (see FIG. 5). As will be described later, this lateral irradiation direction Ds is the direction in which the light forming the lateral irradiation pattern Ps (see FIG. 7 etc.) travels from the side reflection unit 40 to the lateral irradiation region 13s on the projection incident surface 13a. In FIG. 5, for the sake of easy understanding of the lateral irradiation direction Ds, the direction that is approximately the center of the light traveling from the side reflection unit 40 to the lateral irradiation region 13s is shown as the lateral irradiation direction Ds. The side reflection unit 40 is provided to protrude forward in the front-rear direction from the emission surface 38 and has a side reflection surface 41 and a side emission surface 42.

[0023] The side reflection surface 41 is formed on the left surface in the width direction of the side reflection unit 40, and is substantially flat in the first embodiment, and is inclined so as to approach the projection optical axis Lp as it goes toward the side of the projection lens 13. The side reflection surface 41 reflects the light that has been reflected by the reflection curved surface 35ea and then reflected by the upper inner reflection surface 36 toward the side emission surface 42. Note that the side reflection surface 41 may have other configurations as long as it reflects as described above, whether it uses total reflection, performs a reflection process, or otherwise.

[0024] The side emission surface 42 is formed on the right surface in the width direction from the tip of the side reflection unit 40, and is a convex surface that protrudes toward the side of the projection lens 13 in the first embodiment. The side emission surface 42 emits the light reflected by the side reflection surface 41 in the lateral irradiation direction Ds and makes it travel to the lateral irradiation region 13s on the projection incident surface 13a of the projection lens 13, which will be described later.

[0025] The side reflecting surface 41 and the side emitting surface 42 are optically set in consideration of the optical setting of the projection lens 13 so that the emitted light forms a side irradiation pattern Ps (see FIG. 7 etc.) that irradiates the sides of the central irradiation pattern Pc (see FIG. 6 etc.) described later. Specifically, it is set as follows. First, on a screen where the horizontal line H and the vertical line V intersect with the center position O of irradiation (the projection optical axis Lp in the vehicle lamp 10) as the origin, a region as the side irradiation pattern Ps to be formed is set (see FIG. 7 etc.). Next, the traveling direction (angle) for the light emitted from the projection lens 13 to travel to both end positions in the horizontal direction in the side irradiation pattern Ps is obtained. Then, the angular range for the light from the side emitting surface 42 to make the light from the projection lens 13 travel in the above traveling direction is obtained, and the optical settings (curvature, tilt angle, etc.) of the side reflecting surface 41 and the side emitting surface 42 are determined so as to satisfy that angular range. In the first embodiment, the tilt angle is set so that the side reflecting surface 41 is substantially flat and reflects toward the side irradiation region 13s. And the curvature of the side emitting surface 42 is set so that when the reflected light is emitted from the side emitting surface 42, it enters the side irradiation region 13s while satisfying the above angular range. The side emitting surface 42 of the first embodiment is a convex surface so that the emitted light intersects and then enters the side irradiation region 13s of the projection lens 13.

[0026] As shown in FIGS. 1 to 5, the projection lens 13 is provided in front of the light exit surface 38 (light guide exit portion 37) of the light guide lens 12 in the front-rear direction. This projection lens 13 projects the light emitted from the light exit surface 38 forward of the vehicle to form a desired projection light distribution pattern (in the first embodiment, the passing light distribution pattern LP (see FIG. 8)). The projection lens 13 is a molded product made of a transparent resin material. The projection lens 13 is a convex lens inclined so as to go backward as it goes to the right. Specifically, the projection lens 13 is composed of a projection incident surface 13a and a projection exit surface 13b that are a single curved surface and is a convex lens that is double convex. The curvature of the projection incident surface 13a is increased, and the curvature of the projection exit surface 13b is made smaller than that of the projection incident surface 13a. Here, the single curved surface means that there is no bending portion and the change in curvature is continuous. The protruding end of the projection incident surface 13a is displaced to the right in the width direction. The projection exit surface 13b is a gently curved surface that goes forward as it goes to the left while the right side in the width direction is located at the rearmost side. In this projection lens 13, due to the above-described configuration, approximately half of the left side of the projection incident surface 13a is inclined so as to face the side exit surface 42 of the side reflection portion 40, and it is a side irradiation region 13s facing the side exit surface 42. This side irradiation region 13s is a location on the projection incident surface 13a where light that travels from the side reflection portion 40 in the side irradiation direction Ds and forms a side irradiation pattern Ps is incident. Note that the side irradiation region 13s also receives a part of the light that is emitted from the light exit surface 38 and forms the central irradiation pattern Pc, and is not only the light that travels from the side reflection portion 40 in the side irradiation direction Ds that is incident.

[0027] With the projection lens 13 passing through the light exit surface 38 (light guide exit portion 37) of the light guide lens 12, the focal point (rear focal point) is positioned in the vicinity of the cut-off edge portion 36a of the upper internal reflection surface 36. By irradiating the light from the light exit surface 38, the projection lens 13 projects the shape of the upper internal reflection surface 36 including the cut-off edge portion 36a onto the above-described screen. Further, the projection lens 13 irradiates the light that is emitted from the light exit surface 38 after being reflected by the side reflection portion 40 and projects it onto the above-described screen.

[0028] When each light source 21 of this vehicle lamp 10 is lit, the light travels from the corresponding light guide incident portion 31 into the light guide lens 12, is reflected by the lower inner reflection surface 35 and the upper inner reflection surface 36, and then is emitted from the emission surface 38 of the light guide emission portion 37. This light is reflected by the upper inner reflection surface 36, and thus the shape of the cut-off edge portion 36a is reflected. Then, the vehicle lamp 10 projects the light by the projection lens 13. As a result, as shown in FIG. 6, the vehicle lamp 10 has a cut-off line CL on the projection optical axis Lp on the above screen, and can form a central irradiation pattern Pc that brightens a large area in the width direction below the cut-off line CL while making the vicinity of the projection optical axis Lp the brightest.

[0029] At this time, when the vehicle lamp 10 makes the light emitted from the end light source 21E located on the leftmost side of the five light sources 21 travel from the corresponding light guide incident portion 31 into the light guide lens 12, the light travels to the end reflection surface portion 35E of the lower inner reflection surface 35. A part of the light is reflected by the reflection curved surface 35ea of the end reflection surface portion 35E and travels upward in the vertical direction, and then is reflected by the upper inner reflection surface 36 and travels forward in the front-rear direction and travels to the side reflection portion 40. Then, as shown in FIG. 5, a part of the light is reflected by the side reflection surface 41 and emitted from the side emission surface 42 in the side irradiation direction Ds, enters the projection lens 13 from the side irradiation region 13s on the projection incident surface 13a, and is emitted from the projection emission surface 13b. At this time, since the side emission surface 42 and the side irradiation region 13s are opposed to each other, the incident angle of a part of the light with respect to the side irradiation region 13s can be made small, and the light can be surely incident on the projection lens 13. This part of the light irradiates a large area on the right side in the width direction beyond the projection optical axis Lp, and thus forms a side irradiation pattern Ps located on the side of the central irradiation pattern Pc as shown in FIG. 7. This side irradiation pattern Ps brightens a wide area on the right side in its width direction while partially overlapping with the central irradiation pattern Pc (see FIG. 8).

[0030] By lighting the five light sources 21, the vehicle lamp 10 can form a central irradiation pattern Pc having a cut-off line CL and a side irradiation pattern Ps that overlaps a part of the central irradiation pattern Pc and extends to the right in the width direction, as shown in FIG. 8. The central irradiation pattern Pc and the side irradiation pattern Ps form an oncoming vehicle passing light distribution pattern LP that brightens a wide area in the width direction while having the cut-off line CL. This oncoming vehicle passing light distribution pattern LP becomes a projection light distribution pattern that irradiates the front of the vehicle, can illuminate a wide position in the width direction, and can secure a wide range of visibility. Since the central irradiation pattern Pc includes the cut-off line CL, it can be used as an oncoming vehicle passing light distribution pattern alone, but by cooperating with the side irradiation pattern Ps to form the oncoming vehicle passing light distribution pattern LP, a wider position can be illuminated. In this way, the vehicle lamp 10 can form the side irradiation pattern Ps by using a part of the light from the five light sources 21 for forming the central irradiation pattern Pc, and can make the oncoming vehicle passing light distribution pattern LP illuminate a wider position.

[0031] Here, since the vehicle lamp 10 makes the light from each light source 21 enter from each light guide incident portion 31, the light from each light source 21 with a spread can be efficiently made to enter the light guide lens 12. And since the vehicle lamp 10 forms the cut-off line CL while the light guide lens 12 totally reflects the incident light by the lower internal reflection surface 35 and the upper internal reflection surface 36, the oncoming vehicle passing light distribution pattern can be formed while efficiently using the light.

[0032] In addition, the vehicle lamp 10 can form an oncoming vehicle distribution pattern LP that illuminates a wide range of positions with the light guide lens 12 and the projection lens 13 made of a transparent resin material, so that the manufacturing cost can be suppressed while having a simple structure. This is due to the following reasons. In a vehicle lamp, when forming an oncoming vehicle distribution pattern LP, it is conceivable to use a reflector member that reflects light from a light source or a shade member that forms a cut-off line, which leads to an increase in the number of components and the need to prepare materials for each member. However, the vehicle lamp 10 only provides two optical members, the light guide lens 12 and the projection lens 13, and both are made of a transparent resin material. And the vehicle lamp 10 forms a cut-off line CL by utilizing the shape (cut-off edge portion 36a) of the upper internal reflection surface 36 of the light guide lens 12. Therefore, the vehicle lamp 10 can form an oncoming vehicle distribution pattern LP that illuminates a wide range of positions while having a simple structure and suppressing the manufacturing cost.

[0033] Here, the problems of the conventional vehicle lamp technology will be described. The conventional vehicle lamp uses a projection lens configured by connecting a plurality of lens portions having different optical characteristics in the width direction. This conventional vehicle lamp can have optical characteristics adapted to the irradiated locations for each lens portion, so that it can irradiate a wide range of positions in the horizontal direction. However, in the conventional vehicle lamp, the complexity of the projection lens causes an increase in the manufacturing cost. Therefore, it is conceivable to use a projection lens configured by an incident surface and an exit surface that are a single curved surface to avoid complexity and suppress the increase in the manufacturing cost. However, if the vehicle lamp has an incident surface and an exit surface that are a single curved surface, it is difficult to irradiate light to a position away from the projection optical axis in the horizontal direction, and it becomes difficult to irradiate a wide range of positions.

[0034] In contrast, in the vehicle lamp 10 of the present disclosure, a side reflection portion 40 is provided at the left end of the light guide emission portion 37 of the light guide lens 12, and at least a part of the light from the end light source 21E is reflected by the side reflection surface 41 thereof, so as to travel in a side irradiation direction Ds approaching the projection optical axis Lp from the side reflection surface 41. Then, the vehicle lamp 10 makes the light enter the projection lens 13 from the side irradiation region 13s on the projection incident surface 13a and projects the light from the projection lens 13. That is, the vehicle lamp 10 can make the light enter the projection lens 13 in a side irradiation direction Ds with an increased angle with respect to the projection optical axis Lp by reflecting the light on the side emission surface 42 provided at a position closer to the projection lens 13 than each light source 21. And the vehicle lamp 10 can project the light to the opposite side (right side) beyond the projection optical axis Lp by the projection of the projection lens 13. For this reason, the vehicle lamp 10 can irradiate the light to a position away from the projection optical axis Lp in the horizontal direction even with the projection lens 13 composed of the projection incident surface 13a and the projection emission surface 13b which are a single curved surface.

[0035] Further, the vehicle lamp 10 projects the light with an increased angle with respect to the projection optical axis Lp by providing the side reflection portion 40 by protruding the light guide lens 12 forward, so that the light entering the projection lens 13 at such an angle can be provided without causing an increase in size or complexity of the configuration. This is due to the following. In order to make the light at the above angle enter the projection lens 13, it is conceivable to provide a light source on the extension line of that angle. However, if a light source is provided at such a position, it is necessary to provide a substrate separately from the other four light sources, which leads to a complication of the configuration. Also, it is conceivable to extend the substrate up to the extension line of the above angle, but this leads to an increase in size.

[0036] Furthermore, the vehicle lamp 10 positions the end light source 21E and the side reflection portion 40 at the same position when viewed in the width direction, and causes at least a part of the light from the end light source 21E to travel toward the front side in the front-rear direction and then proceed to the side reflection portion 40. For this reason, the vehicle lamp 10 can collect the remaining light from each light source 21 near the cut-off edge portion 36a of the upper internal reflection surface 36 to appropriately form the cut-off line CL, while causing the light to proceed to the side reflection portion 40. Thereby, the vehicle lamp 10 can appropriately form the passing light distribution pattern LP having the cut-off line CL over a wide position in the width direction. In particular, since the vehicle lamp 10 only changes the optical characteristics of the reflecting curved surface 35ea of the end reflecting surface portion 35E of the lower internal reflection surface 35 from those of the other lower internal reflection surfaces 35 (including the reflecting curved surfaces 35eb and 35ec), the vehicle lamp 10 can cause the light to proceed to the side reflection portion 40 with a simple configuration.

[0037] In the projection lens 13 of the vehicle lamp 10, the projection exit surface 13b is an inclined convex lens that inclines rearward as it goes rightward, and the projection entrance surface 13a is a convex surface with a large curvature whose protruding end is displaced rightward in the width direction. For this reason, the vehicle lamp 10 can incline the side irradiation region 13s of the projection entrance surface 13a so as to face the side exit surface 42 side of the side reflection portion 40, and can oppose the side irradiation region 13s and the side exit surface 42 to each other. Thereby, the vehicle lamp 10 can reduce the incident angle of the light emitted from the side exit surface 42 of the side reflection portion 40 with respect to the side irradiation region 13s, and can surely cause the light to enter the projection lens 13.

[0038] The vehicle lamp 10 is provided with a side reflection part 40 at the light guide emission part 37 of the light guide lens 12. Therefore, for the vehicle lamp 10, it is only necessary to assemble the light source part 11, the light guide lens 12, and the projection lens 13. There is no need to provide new assembly members or configurations only for the side reflection part 40, so that the number of assembly members can be reduced and the assembly work can be simplified. Further, in the vehicle lamp 10, since the positional relationship of the side reflection part 40 with respect to each light guide incident part 31 and the emission surface 38 (light guide emission part 37) is determined in advance, the positioning adjustment work can be eliminated and the accuracy of the positional relationship can be improved. Furthermore, the vehicle lamp 10 can efficiently guide the light incident into the light guide lens 12 to the side reflection part 40.

[0039] In the vehicle lamp 10, since the side emission surface 42 of the side reflection part 40 is a convex surface, it is possible to form a shape with a rounded tip while ensuring the dimension in the width direction of the side reflection part 40. Therefore, the vehicle lamp 10 can adjust the degree of diffusion of the light that becomes the side irradiation region 13s according to the shape (degree of curvature) of the convex surface, and it can be made easy to mold the light guide lens 12 using a mold.

[0040] As an example of the vehicle lamp according to the present disclosure, the vehicle lamp 10 can obtain the following respective operational effects.

[0041] The vehicle lamp 10 includes a light guide lens 12 that guides light from a plurality of light sources 21 arranged in the width direction, and a projection lens 13 that projects the light guided there and forms a projection light distribution pattern (a passing light distribution pattern LP for oncoming vehicles) for irradiating the front of the vehicle. The light guide lens 12 has a side reflection portion 40 that partially protrudes toward the projection lens 13 side. The side reflection portion 40 reflects at least a part of the light from the end light source 21E located at the end of the plurality of light sources 21 toward the projection incident surface 13a of the projection lens 13 in the side irradiation direction Ds so as to travel to the horizontal end portion in the projection light distribution pattern. For this reason, the vehicle lamp 10 can make the light incident on the projection lens 13 while making the side irradiation direction Ds in which the angle with respect to the projection optical axis Lp is increased by reflecting the light by the side reflection portion 40 that is located closer to the projection lens 13 than each light source 21 by partially protruding toward the projection lens 13 side in the light guide lens 12. Thereby, the vehicle lamp 10 can irradiate light to a position away from the projection optical axis Lp in the horizontal direction even with the projection lens 13 composed of the projection incident surface 13a and the projection exit surface 13b that are a single curved surface.

[0042] Further, the vehicle lamp 10 includes a side reflection surface 41 in the side reflection portion 40 that reflects at least a part of the light from the end light source 21E, and a side exit surface 42 that emits the light reflected by the side reflection surface 41. The side reflection surface 41 is inclined so as to approach the projection optical axis Lp as it goes toward the projection lens 13 side. The vehicle lamp 10 can make the side irradiation direction Ds in which the angle with respect to the projection optical axis Lp is increased by reflecting at least a part of the light from the end light source 21E by the side reflection surface 41 of the side reflection portion 40, and can emit the light in the side irradiation direction Ds from the side exit surface 42 toward the side irradiation region 13s.

[0043] Furthermore, the vehicle lamp 10 has a projection incident surface 13a as a convex surface protruding toward the light guide lens 12 side. Therefore, the vehicle lamp 10 can incline the lateral irradiation region 13s of the projection incident surface 13a toward the lateral emission surface 42 side of the lateral reflection portion 40, can reduce the incident angle of the light emitted from the lateral emission surface 42 with respect to the lateral irradiation region 13s, and can surely make the light incident on the projection lens 13.

[0044] The vehicle lamp 10 reflects the lateral reflection portion 40 toward the lateral irradiation region 13s facing the lateral emission surface 42 at the projection incident surface 13a. Therefore, the vehicle lamp 10 can make the incident angle of the light emitted from the lateral emission surface 42 of the lateral reflection portion 40 with respect to the lateral irradiation region 13s more appropriate, and can more surely make the light incident on the projection lens 13.

[0045] The vehicle lamp 10 uses a cut-off line CL passing passing glare light distribution pattern LP as a projection light distribution pattern. Further, the vehicle lamp 10 includes a light guide lens 12 having a light guide incident portion 31 for making the light from each light source 21 incident thereon, a first internal reflection surface (lower internal reflection surface 35) for reflecting the light incident therefrom in a crossing direction crossing the optical axis direction along the projection optical axis Lp, a second internal reflection surface (upper internal reflection surface 36) for reflecting the light reflected there in the optical axis direction, and a light guide emission portion 37 for emitting the light reflected there. And the second internal reflection surface (upper internal reflection surface 36) has a cut-off edge portion 36a forming the cut-off line CL. Therefore, the vehicle lamp 10 can form the cut-off line CL of the passing glare light distribution pattern LP by reflecting with the internal reflection surface, and can illuminate a wide range of positions with the passing glare light distribution pattern LP.

[0046] Therefore, the vehicle lamp 10 of Example 1 as the vehicle lamp according to the present disclosure can irradiate a wide range of positions in the horizontal direction using a projection lens 13 in which the projection incident surface 13a and the projection emission surface 13b are a single curved surface.

Embodiment

[0047] Next, the vehicle lamp 10A of Example 2 as an example of the vehicle lamp according to the present disclosure will be described with reference to FIGS. 9 to 16. Since the basic concept and configuration of the vehicle lamp 10A are the same as those of the vehicle lamp 10 of Example 1, the same reference numerals are given to the parts having the same configuration, and detailed description thereof will be omitted.

[0048] First, the vehicle lamp 10A of Example 2 is configured to have the same configuration whether it is provided on the left side or the right side of the vehicle. In the light source unit 11 of Example 2, the first light source 211 and the fifth light source 215 located at both ends in the arranged positional relationship are the end light sources 21E. Each of these end light sources 21E is used for forming a side irradiation pattern Ps (see FIG. 15 etc.) of the emitted light.

[0049] This vehicle lamp 10A has a different configuration of the light guide lens 12A and the projection lens 13A from the vehicle lamp 10 of Example 1. As shown in FIGS. 9 to 13, this light guide lens 12A is provided corresponding to the five light sources 21 of the light source unit 11 and is a molded product made of a transparent resin material. This light guide lens 12A is an optical lens that guides the light emitted from each light source 21 inward and forms a projection light distribution pattern (the light distribution pattern LP for passing (see FIG. 16)) in cooperation with the projection lens 13A. Five light guide incident portions 31 are provided on the rear side in the front-rear direction of the light guide lens 12A.

[0050] Each light guide incident portion 31 corresponds individually to each light source 21 and has optical characteristics (such as the shape of the surface) according to the light distribution image required for each while having basically the same configuration as each other. Similar to Example 1, each of these light guide incident portions 31 allows the light from the corresponding light source 21 to enter from the opposing incident surface 32 and, after entering from the inclined incident surface 33, is reflected by the annular reflecting surface 34 and then enters the light guide lens 12A as parallel light traveling substantially parallel to the axis of the light guide incident portion 31. Each of these lights travels toward the light guide emission portion 37A of the light guide lens 12A.

[0051] The light guide emission part 37A is provided in front of the five light guide incident parts 31 in the front-rear direction. This light guide emission part 37A is concave-curved such that the center in the width direction (projection optical axis Lp) is located at the rearmost position in the front-rear direction, and both ends in the width direction are located at the foremost position in the front-rear direction, and the curved concave surface is the emission surface 38A. The emission surface 38A is in a positional relationship facing the middle three of the five light guide incident parts 31 in the front-rear direction and is substantially along the shape of the image plane in the projection lens 13A.

[0052] At this emission surface 38A, the lower edge part is the cut-off edge part 38Aa. This cut-off edge part 38Aa forms a cut-off line CL and has a shape in which horizontal edges with different heights are joined by inclined edges. This cut-off edge part 38Aa is located near the focal point (rear focal point) of the projection lens 13A. When light is incident from the middle three light guide incident parts 31 on this emission surface 38A, the emission surface 38A emits the light to become bright. At this time, since the emission surface 38A does not emit the light that has traveled below the cut-off edge part 38Aa, the lower side is along the shape of the cut-off edge part 38Aa. Regardless of whether the vehicle lamp 10A is provided on either side of the vehicle, the direction of inclination and the relationship of the height at the cut-off edge part 38Aa are not reversed in the width direction.

[0053] In this light guide emission part 37A, side reflection parts 40A are provided on both sides in the width direction. The side reflection parts 40A emit the light emitted from the two end light sources 21E and incident from the corresponding light guide incident parts 31 to the side irradiation direction Ds inclined with respect to the projection optical axis Lp (see FIG. 13). Each side reflection part 40A is provided with both end parts of the light guide emission part 37A protruding forward in the front-rear direction and has a side reflection surface 41A and a side emission surface 42A.

[0054] Each side reflecting surface 41A is formed on both side surfaces located outside in the width direction of the light guiding emission part 37A, and is substantially flat in the first embodiment, and is inclined so as to approach the projection optical axis Lp as it goes toward the side of the projection lens 13A. Each of these side reflecting surfaces 41A is located in front in the front-rear direction of the two end light sources 21E and the corresponding light guiding incident part 31, and reflects the light from each of them toward the side irradiation direction Ds approaching the projection optical axis Lp. Note that the side reflecting surface 41A may have other configurations as long as it reflects as described above, such as using total reflection, performing reflection processing, or other configurations.

[0055] The side emission surface 42A is formed on the surface on the projection optical axis Lp side of the corresponding side reflecting part 40A, and is located in the side irradiation direction Ds in which the light reflected by the side reflecting surface 41A travels. The side emission surface 42A is a concave surface continuous from the emission surface 38A in the first embodiment. The side emission surface 42A emits the light reflected by the side reflecting surface 41A toward the above-described inclined side irradiation direction Ds, and causes it to travel toward the side irradiation region 13As on the projection incident surface 13Aa of the projection lens 13A described later.

[0056] The optical settings of the side reflecting surface 41A and the side emission surface 42A are determined in consideration of the optical settings of the projection lens 13A so that the emitted light forms both side irradiation patterns Ps1 and Ps2 (see FIGS. 16 etc.) that irradiate the sides of the central irradiation pattern Pc (see FIGS. 14 etc.). The side emission surface 42A of the second embodiment is a concave surface, and is configured to make the light reflected by the side reflecting surface 41A enter the side irradiation region 13As of the projection lens 13A while spreading the light.

[0057] As shown in FIGS. 9 to 13, the projection lens 13A is provided in front of the light-emitting surface 38A (light-guiding light-emitting portion 37A) of the light-guiding lens 12A in the front-rear direction. This projection lens 13A projects the light emitted from the light-emitting surface 38A forward of the vehicle to form a desired projection light distribution pattern (the passing light distribution pattern LP (see FIG. 16) in the first embodiment). The projection lens 13A is a molded product made of a transparent resin material. The projection lens 13A is composed of a projection incident surface 13Aa and a projection exit surface 13Ab that are single curved surfaces and is a convex lens that is double convex. The curvature of the projection incident surface 13Aa is made large, and the curvature of the projection exit surface 13Ab is made smaller than that of the projection incident surface 13Aa. Here, the single curved surface means that there is no bending portion and the change in curvature is continuous. The projection incident surface 13Aa and the projection exit surface 13Ab have their protruding ends located at the center in the width direction. In this projection lens 13A, due to the above-described configuration, both end portions in the width direction of the projection incident surface 13Aa are inclined so as to face the side-emitting surface 42A side of each side reflection portion 40A, and a side irradiation region 13As is formed that faces the side-emitting surface 42A.

[0058] The focal point (rear focal point) of this projection lens 13A is located near the cut-off edge portion 38Aa on the light-emitting surface 38A of the light-guiding lens 12A. By irradiating the light from the light-emitting surface 38A, the projection lens 13A projects the shape of the light-emitting surface 38A including the cut-off edge portion 38Aa onto the above-described screen. Further, the projection lens 13A irradiates the light that has been reflected by the side reflection portion 40A and then emitted from the light-emitting surface 38A, and projects it onto the above-described screen.

[0059] When each light source 21 of this vehicle lamp 10A is lit, the light travels from the corresponding light guide incident portion 31 into the light guide lens 12A and is emitted from the emission surface 38A of the light guide emission portion 37A. This light reflects the shape of the cut-off edge portion 38Aa of the emission surface 38A. Then, the vehicle lamp 10A projects this light by the projection lens 13A. As a result, as shown in FIG. 14, the vehicle lamp 10A forms a first central irradiation pattern Pc1 having a cut-off line CL with the light from the third light source 213. Further, the vehicle lamp 10A forms a second central irradiation pattern Pc2 in which the light from the second light source 212 is displaced to the right while overlapping with the first central irradiation pattern Pc1. Furthermore, the vehicle lamp 10A forms a third central irradiation pattern Pc3 in which the light from the fourth light source 214 is displaced to the left while overlapping with the first central irradiation pattern Pc1. By overlapping these, the vehicle lamp 10A can form a central irradiation pattern Pc having a cut-off line CL on the projection optical axis Lp on the above screen, making the vicinity of the projection optical axis Lp the brightest and brightening a large area in the width direction below the cut-off line CL.

[0060] Also, as shown in FIG. 13, when the light emitted from the two end light sources 21E (the first light source 211 and the fifth light source 215) located at both ends of the vehicle lamp 10A travels from the corresponding light guide incident portion 31 into the light guide lens 12A, the light travels to the corresponding side reflection portion 40A respectively. Then, each light is reflected by the side reflection surface 41 and emitted from the side emission surface 42A in the side irradiation direction Ds, enters the projection lens 13A from the side irradiation region 13As on the projection incident surface 13Aa, and is emitted from the projection emission surface 13Ab. At this time, since the side emission surface 42A and the side irradiation region 13As are opposed to each other, the incident angle of each light with respect to the side irradiation region 13As can be made small, and the light can be surely incident on the projection lens 13A.

[0061] Then, the light from the first light source 211 irradiates a large area on the right side in the width direction beyond the projection optical axis Lp, thereby forming a first side irradiation pattern Ps1 located on the right side of the central irradiation pattern Pc as shown in FIG. 15. This first side irradiation pattern Ps1 brightens a wide area on the right side in its width direction while partially overlapping with the central irradiation pattern Pc (see FIG. 16).

[0062] Also, the light from the fifth light source 215 irradiates a large area on the left side in the width direction beyond the projection optical axis Lp, thereby forming a second side irradiation pattern Ps2 located on the left side of the central irradiation pattern Pc. This second side irradiation pattern Ps2 brightens a wide area on the left side in its width direction while partially overlapping with the central irradiation pattern Pc (see FIG. 16).

[0063] By lighting the five light sources 21 of this vehicle lamp 10A, as shown in FIG. 16, a central irradiation pattern Pc having a cut-off line CL and two side irradiation patterns (Ps1, Ps2) that partially overlap therewith and extend outward in the width direction can be formed. The central irradiation pattern Pc and the side irradiation patterns (Ps1, Ps2) form an oncoming vehicle distribution pattern LP that brightens a wide area in the width direction while having the cut-off line CL. This oncoming vehicle distribution pattern LP becomes a projection distribution pattern that irradiates the front of the vehicle, can illuminate a wide position in the width direction, and can secure a wide range of visibility. Note that since the central irradiation pattern Pc includes the cut-off line CL, it can be used alone as an oncoming vehicle distribution pattern, but by cooperating with the two side irradiation patterns (Ps1, Ps2) to form the oncoming vehicle distribution pattern LP, a wider position can be illuminated. In this way, the vehicle lamp 10A can form the side irradiation pattern Ps by using a part of the light from the five light sources 21 arranged in the width direction, and can make the oncoming vehicle distribution pattern LP illuminate a wider position.

[0064] Since the vehicle lamp 10A causes the light from each light source 21 to enter from each light guide incident portion 31, the light from each light source 21 with a spread can be efficiently made to enter the light guide lens 12. And since the light guide lens 12 of the vehicle lamp 10A directly advances the incident light to the emission surface 38A of the light guide emission portion 37A, the passing light distribution pattern LP can be formed while efficiently using the light.

[0065] The vehicle lamp 10A has the side emission surface 42A of the side reflection portion 40A as a concave surface, and also has the emission surface 38A of the light guide emission portion 37A as a concave surface, and they are a continuous curved surface. For this reason, the vehicle lamp 10A can easily form the emission surface 38A and the side emission surface 42A, and can easily mold the light guide lens 12A using a mold.

[0066] The vehicle lamp 10A of Example 2 can obtain the following respective operational effects. Since this vehicle lamp 10A basically has the same configuration as the vehicle lamp 10 of Example 1, the same effects as Example 1 can be obtained.

[0067] In addition, the vehicle lamp 10A has the passing light distribution pattern LP having the cut-off line CL as a projection light distribution pattern. Also, the vehicle lamp 10 has a light guide incident portion 31 that causes the light from a plurality of light sources 21 to enter, and a light guide emission portion 37A that emits the light incident from the light guide incident portion 31. And the light guide emission portion 37A has a cut-off edge portion 38Aa that forms the cut-off line CL. For this reason, the vehicle lamp 10A can be configured to form the cut-off line CL of the passing light distribution pattern LP by emitting from the light guide emission portion 37A, and can illuminate a wide range of positions with the passing light distribution pattern LP.

[0068] Therefore, the vehicle lamp 10A of Example 2 as the vehicle lamp according to the present disclosure can irradiate a wide range of positions in the horizontal direction using the projection lens 13A in which the projection incident surface 13Aa and the projection emission surface 13Ab are a single curved surface.

[0069] As described above, the vehicle lamp of the present disclosure has been described based on each embodiment. However, the specific configuration is not limited to each embodiment, and design changes, additions, etc. are allowed as long as the gist of the invention according to each claim of the claims is not deviated from.

[0070] Note that, in the vehicle lamp 10 of the first embodiment, a part of the light from the end light source 21E forms the side irradiation pattern Ps, and in the vehicle lamp 10A of the second embodiment, the entire light from each end light source 21E forms each side irradiation pattern Ps. However, it is also possible that the vehicle lamp 10 in the first embodiment uses the entire light from the end light source 21E and the vehicle lamp 10A in the second embodiment uses a part of the light from the end light source 21E, and it is not limited to the configurations of the above-described respective embodiments.

[0071] Also, in each of the above-described embodiments, the passing light distribution pattern LP is formed using five light sources 21. However, as long as a passing light distribution pattern LP that can illuminate a wide range of positions in the width direction is formed using a plurality of light sources in the width direction, the number of the light sources can be appropriately set and is not limited to the configurations of the above-described respective embodiments.

[0072] Furthermore, in each of the above-described embodiments, as the projection light distribution pattern, a passing light distribution pattern LP having a cut-off line CL is formed. However, as long as the projection light distribution pattern irradiates a wide range of positions in the width direction in front of the vehicle, it may be a traveling light distribution pattern that illuminates above the cut-off line, or may be another light distribution pattern, and is not limited to the configurations of the above-described respective embodiments.

[0073] The vehicle lamp 10 of Example 1 forms a central irradiation pattern Pc with the light from four light sources 21 and a part of the light from the first light source 211 serving as the end light source 21E, and forms a side irradiation pattern Ps with the remaining part of the light from the first light source 211. Further, in the vehicle lamp 10A of Example 2, the three central light sources 21 respectively form central irradiation patterns (Pc1, Pc2, Pc3), and side irradiation patterns (Ps1, Ps2) are respectively formed with the light from the first light source 211 and the fifth light source 215 serving as the end light source 21E. However, as long as a side irradiation pattern is formed in at least a part of the light from the end light source 21E in the outermost region of the projection light distribution pattern, the configuration and shape of the central irradiation pattern for each light source may be appropriately set and are not limited to the configuration of each example.

[0074] In each of the above-described examples, the light guide lenses 12, 12A and the projection lenses 13, 13A are configured separately. However, as long as the light guide lenses 12, 12A and the projection lenses 13, 13A function as described above, they may be an integral member and are not limited to the configuration of each example.

Explanation of Reference Numerals

[0075] 10 Vehicle lamp 12, 12A Light guide lens 13, 13A Projection lens 13a Projection incident surface 13s Side irradiation region 21 Light source 21E End light source 31 Light guide incident part 35 Lower internal reflection surface (as an example of the internal reflection surface) 36 Upper internal reflection surface (as an example of the internal reflection surface) 36a Cutoff edge part 37, 37A Light guide exit part 38Aa Cutoff edge part 40 Side reflection part 41 Side reflection surface 42 Side exit surface CL Cutoff line LP Overtaking irradiation pattern (as an example of the projection light distribution pattern) Lp Projection optical axis

Claims

1. A light guide lens that guides light from a plurality of light sources arranged in the width direction, and a projection lens that projects the light guided by the light guide lens to form a projection light distribution pattern that irradiates the front of the vehicle, wherein the light guide lens has a side reflection portion that partially protrudes toward the projection lens side, and the side reflection portion reflects at least a part of the light from an end light source located at an end of the plurality of light sources toward the projection incident surface of the projection lens in a side irradiation direction inclined with respect to the optical axis direction so as to cause the light to travel to the horizontal end portion in the projection light distribution pattern. A vehicle lamp characterized by this.

2. The side reflection portion has a side reflection surface that reflects at least a part of the light from the end light source, and a side emission surface that emits the light reflected by the side reflection surface, The vehicle lamp according to claim 1, wherein the side reflection surface is inclined so as to approach the projection optical axis as it approaches the projection lens side.

3. The vehicle lamp according to claim 2, wherein the projection incident surface is a convex surface that protrudes toward the light guide lens side.

4. The vehicle lamp according to claim 3, wherein the side reflection portion reflects toward a side irradiation region that faces the side emission surface on the projection incident surface.

5. The projection light distribution pattern is a passing light distribution pattern having a cut-off line, The light guide lens has a light guide incident portion that receives light from a plurality of the light sources, a first internal reflection surface that reflects the light incident from the light guide incident portion in an intersecting direction intersecting the optical axis direction, a second internal reflection surface that reflects the light reflected by the first internal reflection surface in the optical axis direction, and a light guide emission portion that emits the light reflected by the second internal reflection surface. The vehicle lamp according to claim 1, wherein the second internal reflection surface has a cut-off edge portion that forms the cut-off line.

6. The projection light distribution pattern is a passing light distribution pattern having a cut-off line, The light guide lens has a light guide incident portion that receives light from a plurality of the light sources, and a light guide emission portion that emits the light incident from the light guide incident portion. The vehicle lamp according to claim 1, wherein the light guide emission portion has a cut-off edge portion that forms the cut-off line.

Images