Vehicle lighting

Abstract

This ensures high strength in the inner lens while suppressing deformation during molding. [Solution] The device comprises a light source that emits light and a control unit having a lens step that controls the light emitted from the light source, and an inner lens formed by injection molding using a mold. The inner lens is formed in a shape that extends in a predetermined direction and has a longitudinal direction, and the inner lens is provided with multiple flange portions that protrude from each part of the outer circumferential surface of the control unit. As a result, the inner lens does not have flange portions that protrude from the entire outer circumferential surface of the control unit, so that deformation during molding can be suppressed while ensuring high strength of the inner lens.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicle lamps in which light emitted from a light source is controlled by an inner lens and then emitted.

Background Art

[0002] Some vehicle lamps are configured such that an inner lens is disposed inside a lamp outer casing composed of a cover and a lamp housing, and light controlled by the inner lens is irradiated outward (see, for example, Patent Document 1). In the vehicle lamp described in Patent Document 1, a lamp member made of a resin material and formed in a shape with a longitudinal direction in the left - right direction is provided as the inner lens, and light is controlled by the control lens portion of the lamp member and irradiated outward.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, the above - mentioned inner lens has a control portion provided with lens steps and a flange portion that functions as a mounting portion to be mounted on a predetermined member such as a holder, and is formed by injection molding using a mold. In addition to functioning as a mounting portion, the flange portion also has a function of enhancing the overall strength of the inner lens.

[0005] However, because the control unit has a lens step, it tends to be thicker than the flange portion. This difference in thickness between the control unit and the flange portion can easily cause a temperature difference between them during cooling in injection molding, and the resulting difference in shrinkage between the control unit and the flange portion may cause deformation. In particular, in shapes with a longitudinal direction, such as inner lenses, the difference in shrinkage can easily cause warping, which may prevent proper control of light in the inner lens.

[0006] Therefore, the vehicle lighting device of the present invention aims to suppress deformation during molding while ensuring high strength of the inner lens. [Means for solving the problem]

[0007] The vehicle lighting device according to the present invention comprises a light source that emits light, and an inner lens formed by injection molding using a mold, which has a control unit having a lens step that controls the light emitted from the light source, wherein the inner lens is formed in a shape that extends in a predetermined direction and has a longitudinal direction, and the inner lens is provided with a plurality of flange portions that protrude from each part of the outer circumferential surface of the control unit.

[0008] This results in a configuration where the inner lens does not have a flange portion that protrudes from the entire outer surface of the control unit. [Effects of the Invention]

[0009] According to the present invention, the inner lens is configured not to have a flange portion that protrudes from the entire outer surface of the control unit, thereby ensuring high strength of the inner lens while suppressing deformation during molding. [Brief explanation of the drawing]

[0010] [Figure 1] Figures 2 to 7 illustrate embodiments of the vehicle lighting device of the present invention, and this figure is a perspective view of the vehicle lighting device. [Figure 2]This is a side view of the lamp unit. [Figure 3] This is a side view of the lamp unit, shown from the opposite side of Figure 2. [Figure 4] This is a perspective view of the inner lens. [Figure 5] This is a perspective view of the inner lens, shown from the opposite side of Figure 4. [Figure 6] This is a front view showing a different inner lens. [Figure 7] This is a front view showing another inner lens. [Modes for carrying out the invention]

[0011] The embodiments for implementing the vehicle lighting device of the present invention will be described below with reference to the attached drawings.

[0012] The following describes the directions of light emission from a vehicle's lighting fixture, with the direction of light emission being forward, and the directions of forward, backward, up, down, left, and right being described. However, the directions of forward, backward, up, down, left, and right shown below are for the convenience of explanation, and the invention is not limited to these directions.

[0013] The vehicle lighting fixture 1 functions, for example, as a headlamp and has the function of illuminating a low beam in a short-range area and a high beam in a long-range area. However, the vehicle lighting fixture 1 may also have the function of illuminating only a low beam, or only a high beam. In addition, the vehicle lighting fixture 1 can be used as other lamps in which the light is controlled and illuminated by an inner lens, in addition to being a headlamp.

[0014] The vehicle lighting fixture 1 comprises a lamp housing 2 having an opening at its front end and a cover 3 that closes the opening of the lamp housing 2 (see Figure 1). The lamp housing 2 and the cover 3 constitute the outer casing 4 of the lighting fixture, and the internal space of the outer casing 4 is formed as the lamp chamber 5.

[0015] A lamp unit 6 is disposed in a lamp chamber 5. The lamp unit 6 includes a heat sink 7 having a heat radiation function, a first substrate 8 and a second substrate 9 respectively attached to the heat sink 7, a holder 10 attached to the heat sink 7, and an inner lens 11 attached to and held by the holder 10 (see FIGS. 1 to 3).

[0016] The heat sink 7 is formed in a horizontally long shape and has an attachment portion 12 having heat radiation fins arranged side by side left and right, a first mechanism connection portion 13 protruding from one side in the lateral direction from the attachment portion 12, a second mechanism connection portion 14 protruding from the other side in the lateral direction from the attachment portion 12, and a third mechanism connection portion 15 protruding rearward from the attachment portion 12.

[0017] The attachment portion 12 is provided with left and right portions as a first portion 12a and a second portion 12b with reference to the central portion in the left - right direction. A first connection hole 13a penetrating through in the front - rear direction is formed in the first mechanism connection portion 13, a second connection hole 14a penetrating through in the front - rear direction is formed in the second mechanism connection portion 14, and a third connection hole 15a penetrating through in the up - down direction is formed in the third mechanism connection portion 15.

[0018] An optical axis adjustment mechanism (aiming adjustment mechanism) not shown having an adjusting screw and a pivot shaft is connected to the first mechanism connection portion 13, the second mechanism connection portion 14, and the third mechanism connection portion 15, and a part of each of the optical axis adjustment mechanisms is inserted into the first connection hole 13a, the second connection hole 14a, and the third connection hole 15a. Therefore, the lamp unit 6 is tilted in the up - down direction and the left - right direction by the operation of the optical axis adjustment mechanism, and the optical axis is adjusted.

[0019] The first substrate 8 is formed in a horizontally long substantially rectangular shape and is attached to the first portion 12a of the attachment portion 12 (see FIG. 2). The lower surface of the first substrate 8 is attached to the front end portion of the first portion 12a. A plurality of first light sources not shown are mounted on the upper surface of the first substrate 8 in a state of being separated left and right.

[0020] The second substrate 9 is formed in a horizontally long substantially rectangular shape and is attached to the second portion 12b of the attachment portion 12 (see FIG. 3). The upper surface of the second substrate 9 is attached to the front end portion of the second portion 12b. A plurality of second light sources (not shown) are mounted on the lower surface of the second substrate 9 in a state of being separated from each other left and right. Incidentally, the second substrate 9 may be attached to the second portion 12b in a state of being inclined with respect to the vertical direction.

[0021] The holder 10 is formed in a horizontally long shape and has a base portion 16 attached to the attachment portion 12 and a holding portion 17 continuous with the front end portion of the base portion 16.

[0022] The base portion 16 has a plate-shaped attachment plate portion 18 facing in the vertical direction, a first reflector portion 19 protruding upward from one half portion of the attachment plate portion 18 in the left-right direction, and a second reflector portion 20 protruding downward from the other half portion of the attachment plate portion 18 in the left-right direction. The front side portions of the first reflector portion 19 and the second reflector portion 20 are each opened.

[0023] The holding portion 17 is formed in a horizontally long frame shape. Positioning pins (not shown) protruding forward are provided at both left and right end portions of the holding portion 17.

[0024] For the holder 10, the attachment plate portion 18 is attached to the attachment portion 12 by screwing or the like, the first reflector portion 19 is positioned above the first light source mounted on the upper surface of the first substrate 8, and the second reflector portion 20 is positioned below the second light source mounted on the lower surface of the second substrate 9. Therefore, the light emitted upward from the first light source is reflected forward by the first reflector portion 19, and the light emitted downward from the second light source is reflected forward by the second reflector portion 20. In a state where the holder 10 is attached to the attachment portion 12, the holding portion 17 is positioned in front of the heat sink 7.

[0025] The inner lens 11 is formed by injection molding using a mold, and the control unit 21, a plurality of first flange portions 22, and a plurality of second flange portions 23 are integrally formed from a resin material (see Figures 4 and 5).

[0026] The control unit 21 has an external shape that is horizontally elongated and rectangular. The rear portion of the control unit 21 is provided as a plurality of first lens steps 24 and a plurality of second lens steps 25, each formed in a predetermined shape. The first lens steps 24 are provided side by side on one half of the control unit 21, with the central part in the left-right direction as the reference point, and the second lens steps 25 are provided side by side on the other half of the control unit 21, with the central part in the left-right direction as the reference point.

[0027] The portion of the outer circumferential surface 26 of the control unit 21 corresponding to the boundary between the first lens step 24 and the second lens step 25 is formed as a step boundary portion 26a.

[0028] The first flange portion 22 partially protrudes upward or downward from the middle portion of the control unit 21 in the left-right direction, and is formed, for example, in the shape of a horizontally elongated rectangular block. For example, four first flange portions 22 are provided spaced apart in the upper, lower, left, and right directions, and are continuous with the outer circumferential surface 26 of the control unit 21. The thickness of the first flange portion 22 is thinner than the thickness of the control unit 21, and is continuous with the outer circumferential surface 26 of the control unit 21, for example, excluding the front end.

[0029] The second flange portion 23 extends outward from both the left and right ends of the control unit 21 and is formed, for example, in a U-shape. The second flange portion 23 consists of a vertical portion 23a extending vertically and a pair of horizontal portions 23b projecting laterally in the same direction from both the upper and lower ends of the vertical portion 23a. The vertical portion 23a is continuous with the left and right sides of the control unit 21, and the pair of horizontal portions 23b are continuous with the upper and lower surfaces of the control unit 21, respectively. The thickness of the second flange portion 23 is thinner than the thickness of the control unit 21 and is continuous with, for example, the portion of the outer peripheral surface 26 of the control unit 21 excluding the front end.

[0030] The second flange portion 23 has a positioning hole 23c that penetrates from front to back. The positioning hole 23c is formed, for example, at the boundary between the vertical portion 23a and the horizontal portion 23b of the second flange portion 23.

[0031] The inner lens 11 is provided with, for example, six first flange portions 22 and two second flange portions 23 in total. However, these are not located in a position corresponding to the center of the control unit 21 in the left-right direction. Instead, they are located in positions symmetrical to the center of the control unit 21 in the left-right direction. That is, the inner lens 11 has two first flange portions 22 and one second flange portion 23 on the left half, and two first flange portions 22 and one second flange portion 23 on the right half. Neither the first flange portions 22 nor the second flange portions 23 protrude beyond the step boundary portion 26a.

[0032] As described above, the inner lens 11 has multiple first flange portions 22 and multiple second flange portions 23 provided on the outer circumference of the control unit 21, thereby ensuring high strength of the inner lens 11. In particular, since the first flange portions 22 and the second flange portions 23 are provided in positions symmetrical with respect to the center of the control unit 21 in the left-right direction, the strength of the inner lens 11 is more easily maintained evenly in the longitudinal direction, making it less likely for distortion to occur in the longitudinal direction and ensuring high overall strength of the inner lens 11.

[0033] Furthermore, as described above, the inner lens 11 is integrally formed by injection molding using a mold, with the control unit 21, the first flange portion 22, and the second flange portion 23. Since the control unit 21 is thicker than the first flange portion 22 and the second flange portion 23, the difference in thickness may cause a difference in shrinkage due to the temperature difference during cooling in injection molding. However, the inner lens 11 does not have a flange portion on the entire outer circumference of the control unit 21, but rather has multiple first flange portions 22 and multiple second flange portions 23 spaced apart in the circumferential direction. Therefore, the effect of the temperature difference during cooling in injection molding is suppressed, and deformation of the inner lens 11 is less likely to occur during cooling in injection molding.

[0034] The inner lens 11 is provided with four rectangular first flange portions 22, but the number and size of the first flange portions 22 provided on the inner lens 11 are arbitrary, and it is sufficient that the inner lens 11 has at least one first flange portion 22 on the upper side and one on the lower side of the control unit 21.

[0035] The inner lens 11 is positioned relative to the holder 10 by inserting positioning pins provided in the holder portion 17 of the holder 10 into positioning holes 23c, and the first flange portion 22 is welded (laser welded) to the front surface of the holder portion 17 and attached (see Figures 1 to 3). Thus, the first flange portion 22 of the inner lens 11 functions as the part to be attached to the holder 10, and the second flange portion 23 functions as the positioning part that positions the inner lens relative to the holder 10.

[0036] In the vehicle lighting device 1 configured as described above, when light is emitted from the first light source, the emitted light is reflected forward by the first reflector portion 19 of the holder 10 and incident on the first lens step 24 of the inner lens 11. The light incident on the first lens step 24 is controlled by the first lens step 24 and emitted from the control unit 21, passing through the cover 3 and illuminating forward.

[0037] Furthermore, when light is emitted from the second light source, the emitted light is reflected forward by the second reflector portion 20 of the holder 10 and incident on the second lens step 25 of the inner lens 11. The light incident on the second lens step 25 is controlled by the second lens step 25 and emitted from the control unit 21, passing through the cover 3 and illuminating forward.

[0038] In the vehicle lighting fixture 1, a low beam is emitted when light is emitted only from the first light source and passes through the cover 3, and a high beam is emitted when light is emitted simultaneously from the first light source and the cover 3 passes through.

[0039] The above shows an example of an inner lens 11 provided with multiple first flange portions 22 and multiple second flange portions 23. However, it is also possible to use an inner lens 11A, for example, which does not have the second flange portions 23, instead of the inner lens 11 (see Figure 6).

[0040] The inner lens 11A has, for example, four first flange portions 22 on the outer circumference of the control unit 21. The four first flange portions 22 are spaced apart vertically and horizontally, similar to the inner lens 11, and are positioned symmetrically with respect to the center of the control unit 21 in the left-right direction. Positioning holes 27 are formed at both the left and right ends of the inner lens 11A into which positioning pins are inserted.

[0041] Similar to the inner lens 11, the inner lens 11A does not have a flange portion on the entire outer circumference of the control unit 21, but rather has multiple first flange portions 22 spaced apart from each other. This suppresses the effect of temperature differences during cooling in injection molding, making it less likely for the inner lens 11A to deform during cooling in injection molding.

[0042] Although the inner lens 11A is provided with four rectangular first flange portions 22, the number and size of the first flange portions 22 provided on the inner lens 11A are arbitrary, and it is sufficient that the inner lens 11A has at least one first flange portion 22 on the upper side and one on the lower side of the control unit 21.

[0043] Furthermore, for example, it is also possible to use an inner lens 11B in which the first flange portion 22 is not provided instead of the inner lens 11 (see Figure 7).

[0044] The inner lens 11B has, for example, two second flange portions 23B on the outer circumference of the control unit 21. The two second flange portions 23B are, for example, positioned symmetrically with respect to the center of the control unit 21 in the left-right direction, similar to the inner lens 11. However, in the inner lens 11B, it is desirable that the length of the horizontal portion 23b of the second flange portion 23B in the left-right direction be longer than the length of the horizontal portion 23b of the inner lens 11 in the left-right direction, in order to increase the overall strength of the inner lens 11B. The inner lens 11B has a positioning hole 23c formed in the second flange portion 23B into which a positioning pin is inserted.

[0045] Similar to the inner lens 11 and inner lens 11A, the inner lens 11B does not have a flange portion on the entire outer circumference of the control unit 21, but rather has multiple second flange portions 23B spaced apart from each other. This suppresses the effect of temperature differences during cooling in injection molding, making it less likely for the inner lens 11B to deform during cooling in injection molding.

[0046] As described above, the vehicle lighting device 1 is provided with an inner lens 11 (including inner lens 11A and inner lens 11B; the same applies hereinafter) having a control unit 21 on which a first lens step 24 and a second lens step 25 for controlling light are formed. The inner lens 11 is formed in a shape that extends in a predetermined direction and has a longitudinal direction, and the inner lens 11 is provided with a plurality of first flange portions 22 and second flange portions 23 that protrude from each part of the outer peripheral surface 26 of the control unit 21.

[0047] Therefore, since the inner lens 11 is configured not to have a flange portion that protrudes from the entire outer circumference of the control unit 21, it is possible to ensure high strength of the inner lens 11 while suppressing deformation during molding.

[0048] Furthermore, the inner lens 11 has a first lens step 24 for low beam and a second lens step 25 for high beam. The inner lens 11 is prone to deformation at the boundary between the first lens step 24 and the second lens step 25. However, by providing the inner lens 11, which has the first lens step 24 and the second lens step 25, with a plurality of first flange portions 22 and second flange portions 23, deformation of the inner lens 11 can be effectively suppressed.

[0049] Furthermore, the first flange portion 22 and the second flange portion 23 protrude from the portion of the outer peripheral surface 26 of the control unit 21 other than the step boundary portion 26a.

[0050] Therefore, since the first lens step 24 and the second lens step 25 do not protrude from the step boundary portion 26a, the boundary portion of the inner lens 11 between the first lens step 24 and the second lens step 25 is less likely to bend, and deformation of the inner lens 11 can be suppressed more effectively.

[0051] In particular, the boundary between the first lens step 24 and the second lens step 25 is the central part in the longitudinal direction of the inner lens 11, and if this boundary part bends, the deformation of both ends in the longitudinal direction of the inner lens 11 will increase. Therefore, by configuring the first lens step 24 and the second lens step 25 so that they do not protrude from the step boundary portion 26a, the overall deformation of the inner lens 11 can be suppressed more effectively.

[0052] Furthermore, multiple first flange portions 22 and second flange portions 23 are provided in positions symmetrical with respect to the center of the inner lens 11 in the longitudinal direction.

[0053] Therefore, since the multiple first flange portions 22 and second flange portions 23 are provided in symmetrical positions in a configuration where they do not protrude from the step boundary portion 26a, deformation of the inner lens 11 can be more effectively suppressed while ensuring a good overall balance of strength for the inner lens 11.

[0054] In addition, the inner lens 11 is provided with a first flange portion 22 located in the middle of its longitudinal direction and second flange portions 23 located at both ends of its longitudinal direction. The first flange portion 22 of the inner lens 11 is attached to the holder 10 by laser welding, and the second flange portions 23 are provided as positioning portions relative to the holder 10.

[0055] Therefore, in the inner lens 11 which is formed in a longitudinal shape, the middle part is attached to the holder 10 and both ends are positioned relative to the holder 10, so that a stable mounting state can be ensured while ensuring high positioning accuracy of the inner lens 11 relative to the holder 10. [Explanation of Symbols]

[0056] 1. Vehicle lighting fixtures 10 holders 11 Inner Lens 21 Control Unit 22 First flange section 23 Second flange section 24 First Lens Step 25 Second Lens Step 26 Outer surface 26a Step boundary 11A Inner Lens 11B Inner Lens 23B Second flange section

Claims

1. A light source that emits light, The system comprises a control unit having a lens step that controls the light emitted from the light source, and an inner lens formed by injection molding using a mold, The inner lens is formed to have a shape that extends in a predetermined direction and has a longitudinal direction. The inner lens is provided with a plurality of flange portions that protrude from various parts of the outer circumferential surface of the control unit. Vehicle lighting fixtures.

2. The aforementioned lens step includes a first lens step for the low beam and a second lens step for the high beam. A vehicle light fixture according to claim 1.

3. The first lens step and the second lens step are positioned side by side in the longitudinal direction of the inner lens. A portion of the outer surface of the control unit corresponding to the boundary between the first lens step and the second lens step is formed as a step boundary portion. The flange portion extends from a portion other than the step boundary portion. The vehicle lighting fixture according to claim 2.

4. Multiple flange portions are provided in positions symmetrical with respect to the center of the inner lens in the longitudinal direction. A vehicle light fixture according to claim 3.

5. A holder for holding the inner lens is provided. Multiple flange portions are provided, including a first flange portion located in the middle of the inner lens in the longitudinal direction and second flange portions located at both ends of the inner lens in the longitudinal direction. The inner lens is attached to the holder by laser welding at the first flange portion. The second flange portion is provided as a positioning portion for the holder. A vehicle light fixture according to claim 1, claim 2, claim 3, or claim 4.

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