Vehicle lighting fixtures and methods for manufacturing vehicle lighting fixtures

Abstract

This invention provides a technology that can reduce or eliminate the generation of foreign matter inside vehicle lighting fixtures. [Solution] The vehicle light fixture comprises an inner lens 24 and first and second members. The inner lens 24 has a first lance hole 242a and a second lance hole 242b arranged in the front-rear direction of the light fixture, the second lance hole 242b is located on the rear side of the light fixture of the first lance hole 242a, the first lance 28a of the first member enters the first lance hole 242a, and the second lance 22b of the second member enters the second lance hole 242b, the first member and the second member can be assembled to the inner lens 24 only from the rear side of the light fixture, and the first lance 28a of the first member cannot enter the second lance hole 242b of the second member.

Description

Technical Field

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[0001] The present disclosure relates to a vehicle lamp and a method for manufacturing a vehicle lamp.

Background Art

[0002] Patent Document 1 discloses a vehicle lamp in which an inner lens is housed in a lamp chamber, which is a space between a lamp body and an outer cover.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The present disclosure has been made in such a situation, and one of its exemplary purposes is to provide a vehicle lamp that can suppress the space in the lamp chamber required for assembling the inner lens and that allows easy assembly of the inner lens.

Means for Solving the Problems

[0005] To solve the above problems, a vehicle lamp according to an aspect of the present disclosure includes an inner lens, a first member, and a second member. The inner lens has a first lance hole and a second lance hole arranged in the front-rear direction of the lamp. The second lance hole is located on the rear side of the lamp of the first lance hole, the first lance of the first member enters the first lance hole, the second lance of the second member enters the second lance hole, the first member and the second member can be assembled to the inner lens only from the rear side of the lamp, and the first lance of the first member cannot enter the second lance hole of the second member.

[0006] Another aspect of the present disclosure is a method for manufacturing a vehicle lamp. This method is a method for manufacturing a vehicle lamp as described above, comprising the steps of preparing a plurality of components of a vehicle lamp, including an inner lens, a first member and a second member, and assembling the plurality of prepared components. The preparation step includes forming the first member and the second member such that the first lance cannot enter the second lance hole, and the assembly step includes assembling the first member to the inner lens from the rear of the lamp and assembling the second member to the inner lens from the direction of the lamp. [Effects of the Invention]

[0007] According to this disclosure, it is possible to provide a vehicle lighting fixture that reduces the space required inside the lamp chamber for assembling the inner lens and facilitates the assembly of the inner lens. [Brief explanation of the drawing]

[0008] [Figure 1] This is a schematic front view of a lighting fixture according to an embodiment. [Figure 2] Figure 1 is a schematic cross-sectional view of the lighting fixture along line AA. [Figure 3] Figure 2 is an exploded perspective view of the lighting unit. [Figure 4] Figure 2 is a top view of the inner lens. [Figure 5] Figure 2 is a perspective view of the tongue-shaped extension of the luminaire unit and its surrounding area, seen from the rear side of the luminaire. [Figure 6] Figure 2 is a perspective view of the tongue-shaped extension of the luminaire unit and its surrounding area, seen from the rear side of the luminaire. [Figure 7] Figure 2 is a perspective view of the tongue-shaped extension of the luminaire unit and its surrounding area, seen from the rear side of the luminaire. [Figure 8] Figures 8(a) to 8(d) show a time-series diagram illustrating part of the process of assembling multiple components of a vehicle lighting fixture. [Modes for carrying out the invention]

[0009] The present disclosure will be described below with reference to the drawings, based on preferred embodiments. The embodiments are illustrative and not limiting, and not all features or combinations thereof described in the embodiments are necessarily essential to the disclosure. The same or equivalent components, members, and processes shown in each drawing will be denoted by the same reference numerals, and redundant descriptions will be omitted where appropriate.

[0010] In this specification, when terms indicating direction such as "up," "down," "front," "rear," "left," and "right" are used, they refer to the direction in which the vehicle light fixture is positioned when mounted on a vehicle.

[0011] Figure 1 is a schematic front view of a vehicle light fixture 1 according to an embodiment. The vehicle light fixture 1 shown in Figure 1 may be located at the front of the vehicle or at the rear of the vehicle.

[0012] When the vehicle light fixture 1 is positioned at the front of the vehicle, it can be used, for example, as a turn signal lamp, clearance lamp, or daytime running lamp. In this case, the vehicle light fixture 1 may include a headlight unit (not shown) configured to provide low beam and high beam functions.

[0013] When the vehicle light fixture 1 is positioned at the front of the vehicle, it can be used, for example, as a stop lamp or a tail lamp.

[0014] The vehicle lighting fixture 1 comprises a lamp body 10, a transparent outer cover 12 that covers the front opening of the lamp body 10, and a lighting unit 16 positioned in the lighting chamber 14, which is the space between the lamp body 10 and the outer cover 12. The vehicle lighting fixture 1 also further comprises a headlight unit 18.

[0015] The headlight unit 18 is configured to provide low beam and high beam functions. Additionally, or alternatively to the high beam function, the headlight unit 18 may be configured to provide an adaptive high beam function that forms an optimal orientation pattern according to the situation around the vehicle.

[0016] The lamp unit 16 can be used as, for example, a DRL (Daytime Running Lamp), a clearance lamp, or a turn signal lamp. When the vehicle lamp 1 is disposed at the rear of the vehicle, the lamp unit 16 can be used as a marker lamp at the rear of the vehicle, for example, a turn signal lamp, a tail lamp, or a stop lamp.

[0017] FIG. 2 is a schematic cross-sectional view of the lamp unit 16. FIG. 2 corresponds to a cross-sectional view taken along line A-A in FIG. 1. FIG. 3 is an exploded perspective view of the lamp unit 16. In FIG. 3, the display of the extension member 26 is omitted.

[0018] The lamp unit 16 includes a light source (not shown), a light guide 20, a reflector 22, an inner lens 24, an extension member 26, and a base member 28.

[0019] The light source is typically an LED (Light emitting diode), but may also be other semiconductor light emitting elements such as an LD (Laser diode), an organic EL (Electro luminescence), or an inorganic EL, or a bulb, an incandescent lamp (halogen lamp), or a discharge lamp (discharge lamp).

[0020] The light guide 20 is a long, rod-shaped member that generally extends in the vehicle width direction. The light guide 20 is made of a light-transmitting resin material, such as acrylic resin or polycarbonate resin. The light guide 20 has an incident surface 20a, which is one end face, an other end face 20b, and a circumferential surface 20c connecting these two end faces. The light guide 20 is positioned such that the incident surface 20a is located on the outside in the vehicle width direction, and the other end face 20b is located towards the center in the vehicle width direction, with the center side being further forward of the vehicle. A light source (not shown) is positioned opposite the incident surface 20a. Light emitted from the light source enters the light guide 20 from the incident surface 20a.

[0021] The reflector 22 is a long member that generally extends in the vehicle width direction. The reflector 22 is formed of polycarbonate resin, although this is not always the case. The reflector 22 has a reflective surface 22a facing the front of the lamp. The reflective surface 22a is formed, for example, by vapor deposition. The reflector 22 supports the light guide 20 and reflects the light that leaks from the light guide 20 to the rear of the lamp back to the front of the lamp. This increases the efficiency of light utilization from the light source. The reflector 22 is fixed to the lamp body 10.

[0022] The inner lens 24 is a long member that generally extends in the vehicle width direction. The inner lens 24 is formed of acrylic resin, although this is not always the case. The inner lens 24 is positioned on the front side of the light luminaire of the light guide so as to conceal the light guide 20. The inner lens 24 is light-transmitting and transmits light emitted from the light guide 20. The inner lens 24 may be colorless, or it may have an appropriate color depending on the application of the vehicle luminaire 1. The inner lens 24 may be configured to diffuse light. For example, a diffusing agent may be incorporated into the inner lens 24, or the surface of the inner lens 24 may be textured to diffuse light. In this embodiment, the inner lens 24 is formed of acrylic resin.

[0023] The extension member 26 is a decorative component that covers a part of the structure located inside the lamp chamber 14, making it invisible from the outside of the vehicle lamp 1. The extension member 26 is fixed to the lamp body 10.

[0024] The base member 28 supports the light source. The base member 28 is fixed to the extension member 26. The base member 28 is formed of polycarbonate resin, but is not limited to that.

[0025] Light emitted from the light source enters the light guide 20 from the incident surface 20a, and travels through the light guide 20 toward the other end surface 20b while repeatedly undergoing internal reflection on the circumferential surface 20c. While traveling through the light guide 20, the light is emitted either toward the front of the lamp or toward the rear of the lamp and reflected toward the front of the lamp by the reflective surface 22a of the reflector 22. In either case, the light emitted from the light guide 20 travels toward the front of the lamp, passes through the inner lens 24, and is emitted out of the vehicle lamp 1.

[0026] The above describes the basic configuration of the vehicle lighting device 1.

[0027] Next, the fixing structure of the inner lens 24 will be described in detail. Refer to Figures 4-7 in addition to Figures 2 and 3.

[0028] Figure 4 is a top view of the inner lens 24 of Figure 2. Figures 5-7 are perspective views of the tongue-shaped extension 242 and its surroundings of the luminaire unit 16, viewed from the rear side of the luminaire. In Figure 5, the reflector 22, base member 28, and extension member 26 are omitted. In other words, Figure 5 shows the inner lens 24 by itself. In Figure 6, the reflector 22 is omitted.

[0029] The inner lens 24 has a tongue-shaped extension 242 that extends rearward from the main body 241 on the rear side of the luminaire. The tongue-shaped extension 242 is a substantially flat fixing portion. Two lance holes 242a and 242b are formed in the tongue-shaped extension 242, which are aligned in the front-to-rear direction of the luminaire. The two lance holes 242a and 242b penetrate the tongue-shaped extension 242 in the vertical direction. The first lance hole 242a is located in front of the second lance hole 242b in the front-to-rear direction of the luminaire.

[0030] The base member 28 has a first lance 28a which is a projection that protrudes downward. The reflector 22 has a second lance 22b which is a projection that protrudes upward.

[0031] The first lance 28a of the base member 28 engages with, or enters, the first lance hole 242a. This fixes the inner lens 24 to the base member 28 and, consequently, to the extension member 26. The second lance 22b of the reflector 22 engages with, or enters, the second lance hole 242b. This fixes the inner lens 24 to the reflector 22 and, consequently, to the lamp body 10.

[0032] The first lance 28a enters the first lance hole 242a from above. The second lance 22b enters the second lance hole 242b from below. In other words, the first lance 28a and the second lance 22b enter the lance holes 242a and 242b from opposite sides in the vertical direction.

[0033] The first lance 28a does not penetrate the first lance hole 242a, except in this case. Therefore, the first lance hole 242a does not need to be a through hole and may be a non-through hole, in this example a non-through hole that is recessed downwards. The second lance 22b does not penetrate the second lance hole 242b, except in this case. Therefore, the second lance hole 242b does not need to be a through hole and may be a non-through hole, in this example a non-through hole that is recessed upwards.

[0034] The inner lens 24 is fixed to the reflector 22 and, consequently, to the lamp body 10, by having the second lance 22b of the reflector 22 enter the second lance hole 242b of the inner lens 24. More specifically, the inner lens 24 is restricted from moving forward by the reflector 22.

[0035] As will be described later, in order to assemble the inner lens 24 to the extension assembly, it is necessary to insert the first lance 28a into the first lance hole 242a. However, since the inner lens 24 is ultimately fixed by the reflector 22, there is ultimately no point in inserting the first lance 28a into the first lance hole 242a. In other words, the first lance 28a is inserted into the first lance hole 242a for temporary fixing. Therefore, the amount that the first lance 28a penetrates into the first lance hole 242a does not need to be as much as that that of the second lance 22b. That is, the second lance 22b penetrates into the second lance hole 242b relatively deeply, while the first lance 28a may penetrate into the first lance hole 242a relatively shallowly. In this case, it becomes easier to assemble the base member 28 to the inner lens 24.

[0036] The base edges of the first lance 28a and the second lance 22b are recessed. The base edge of the first lance 28a is recessed upwards, and the base edge of the second lance 22b is recessed downwards. As a result, the first lance 28a and the second lance 22b are easily deformed.

[0037] The first lance 28a and the second lance hole 242b are configured such that the first lance 28a cannot enter the second lance hole 242b. However, in the illustrated example, this is achieved by the fact that the widthwise dimension of the second lance hole 242b is smaller than the widthwise dimension of the first lance 28a.

[0038] As described above, the first lance 28a enters the first lance hole 242a, and the second lance 22b enters the second lance hole 242b. Therefore, naturally, the widthwise dimension of the first lance hole 242a is larger than the widthwise dimension of the first lance 28a, and the widthwise dimension of the second lance hole 242b is larger than the widthwise dimension of the second lance 22b.

[0039] Next, we will explain how to manufacture the vehicle lighting fixture 1 configured as described above.

[0040] The manufacturing method for the vehicle light fixture 1 comprises the steps of preparing a plurality of components for the vehicle light fixture 1, including an inner lens 24, a base member 28, and a reflector 22, and assembling the prepared plurality of components.

[0041] Providing multiple components for the vehicle lighting device 1 includes forming the base member 28 and the reflector 22 such that the dimension of the second lance hole 242b in the vehicle width direction is smaller than the dimension of the first lance 28a in the vehicle width direction, so that the first lance 28a cannot enter the second lance hole 242b.

[0042] Figures 8(a) to 8(d) show a time-series diagram illustrating part of the process of assembling multiple components of the vehicle lighting fixture 1.

[0043] As shown in Figure 8(a), the inner lens 24 is fixed to the extension member 26, for example, with a screw.

[0044] As shown in Figure 8(b), the base member 28 is assembled to the inner lens 24 from the rear side of the lamp. At this time, the first lance 28a of the base member 28 passes over the second lance hole 242b and enters the first lance hole 242a. Hereinafter, the assembly in which the inner lens 24 and the base member 28 are assembled to the extension member 26 will be referred to as the extension assembly.

[0045] As shown in Figure 8(c), the light guide 20 is fixed to the reflector 22. The light guide 20, to which the reflector 22 is fixed, is then fixed to the lamp body 10 (not shown). Hereinafter, the assembly in which the reflector 22 and the light guide 20 are assembled to the lamp body 10 will be referred to as the body assembly.

[0046] As shown in Figure 8(d), the extension assembly is assembled to the body assembly from the front. Conversely, the body assembly is assembled to the extension assembly from the rear. In other words, the reflector 22 is assembled to the inner lens 24 from the rear side of the lamp. At this time, the second lance 22b of the reflector 22 enters the second lance hole 242b of the inner lens 24.

[0047] By the way, when assembling the base member 28 to the inner lens 24 in Figure 8(b), it is necessary to pass the first lance 28a of the base member 28 over the second lance hole 242b of the inner lens 24. However, if the first lance 28a enters the second lance hole 242b at this time, the vehicle lighting fixture 1 cannot be assembled correctly or the assembly will be delayed.

[0048] One could consider forming the first lance hole 242a and the second lance hole 242b offset in the vehicle width direction to prevent the first lance 28a from entering the second lance hole 242b. However, if the first lance hole 242a and the second lance hole 242b are formed offset in the vehicle width direction, the space required within the lamp chamber 14 for assembling the inner lens 24 will increase, reducing the housing efficiency within the lamp chamber 14.

[0049] In contrast, in this embodiment, although the first lance hole 242a and the second lance hole 242b are formed to be aligned in the front-rear direction of the vehicle, the first lance 28a cannot enter the second lance hole 242b. Specifically, the first lance 28a cannot enter the second lance hole 242b due to its dimensions. Therefore, when assembling the base member 28 to the inner lens 24, the first lance 28a is prevented from entering the second lance hole 242b.

[0050] The present disclosure has been described above based on embodiments. These embodiments are illustrative, and it will be understood by those skilled in the art that various modifications are possible in combinations of their components and processing processes, and that such modifications are also within the scope of the present disclosure. Such modifications will be described below.

[0051] In the embodiment, the case in which the base member 28 has a first lance was described, but the invention is not limited to this, and other components (first members) of the vehicle lamp 1 may also have a first lance. Also, in the embodiment, the case in which the reflector 22 has a second lance was described, but the invention is not limited to this, and other components (second members) of the vehicle lamp 1 may also have a second lance. In this case, the first lance and the second lance may enter the lance holes 242a and 242b from opposite sides in the vertical direction, as in the embodiment, or they may enter the lance holes 242a and 242b from the same direction, that is, both from the top or both from the bottom. Note that the first member and the second member are separate members. However, the first member and the second member are formed of polycarbonate resin.

[0052] Any combination of the embodiments and modifications described above is also useful as an embodiment of the present invention. The new embodiments resulting from these combinations possess the combined effects of the respective embodiments and modifications. Furthermore, it will be understood by those skilled in the art that the functions to be performed by each component described in the claims can be achieved by each component shown in the embodiments and modifications individually or in combination thereof. [Explanation of Symbols]

[0053] 1 Vehicle light fixture, 10 Lamp body, 22 Reflector, 22b Second lance, 24 Inner lens, 28 Base member, 28a First lance, 242a First lance hole, 242b Second lance hole.

Claims

1. Inner lens and First and second members, Equipped with, The inner lens has a first lance hole and a second lance hole arranged in the front-to-back direction of the lamp, The second lance hole is located on the rear side of the first lance hole. The first lance of the first member enters the first lance hole. The second lance of the second member is inserted into the second lance hole. The first and second members can be assembled to the inner lens only from the rear side of the lamp, The first lance of the first member cannot enter the second lance hole of the second member. Vehicle lighting fixtures.

2. The vehicle light fixture according to claim 1, wherein the amount of the first lance entering the first lance hole is less than the amount of the second lance entering the second lance hole.

3. The periphery of the bases of the first lance and the second lance is recessed, as described in claim 1 for a vehicle light fixture.

4. The second member is a reflector that supports the light guide and reflects the light from the light guide toward the inner lens. The vehicle light fixture according to claim 1, wherein the first lance enters the first lance hole from the opposite side of the second lance in the vertical direction.

5. The inner lens is made of acrylic resin, The first and second members are made of polycarbonate resin. A vehicle light fixture according to claim 1.

6. A method for manufacturing a vehicle light according to any one of claims 1 to 5, The steps include preparing a plurality of components of the vehicle lighting device, including the inner lens, the first member and the second member, The steps include assembling the aforementioned multiple components, Equipped with, The aforementioned preparation step includes forming the first member and the second member such that the first lance cannot enter the second lance hole, The aforementioned assembly step is, The steps include assembling the first member to the inner lens from the rear of the lamp, The steps include assembling the second member to the inner lens from the direction of the lamp, including, A method for manufacturing vehicle lighting fixtures.

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