Vehicle headlights

Abstract

The system suppresses the generation of dazzling light while ensuring high brightness of the light emitted outwards. [Solution] The device comprises a plurality of light sources, each emitting light; a plurality of reflectors, each reflecting the light emitted from the plurality of light sources and arranged in a predetermined direction; a projection lens that projects the light reflected by the reflectors; and a light-shielding wall positioned between adjacent reflectors between the projection lens and the reflectors. The light-shielding wall is composed of a first light-shielding section and a second light-shielding section positioned vertically. A first space is formed below the first light-shielding section through which a portion of the light emitted from the light source is transmitted, and a second space is formed above the second light-shielding section through which a portion of the light emitted from the light source is transmitted.

Description

Technical Field

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[0001] The present invention relates to the technical field of vehicle headlights in which light emitted from a plurality of light sources is reflected by reflectors and projected by a projection lens respectively.

Background Art

[0002] In vehicle headlights, a plurality of light sources that emit light and a plurality of reflectors are arranged inside a lamp outer casing composed of a cover and a lamp housing, and the light emitted from the plurality of light sources is reflected by the reflectors respectively and controlled by a projection lens for irradiation (see, for example, Patent Document 1 and Patent Document 2).

[0003] In the vehicle headlights described in Patent Document 1 and Patent Document 2, a plurality of light sources and a plurality of reflectors are arranged, and the light emitted from the plurality of light sources is reflected by the reflectors respectively and controlled by one projection lens for irradiation. The light reflected by each reflector is incident on separate portions of the projection lens, and is made into parallel light or substantially parallel light by the projection lens and irradiated outward.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] By the way, in vehicle headlights configured such that light is reflected by a plurality of reflectors as described above, since the plurality of reflectors are arranged side by side, there is a risk that a part of the reflected light is incident on an unintended part of the projection lens.

[0006] Specifically, for example, in a configuration where light reflected by a first, second, and third reflector positioned in sequence is incident on and controlled by the first, second, and third parts of the projection lens, respectively, there is a risk that light reflected by the first reflector or the third reflector may be incident on the second part, or that light reflected by the second reflector may be incident on the first or third part.

[0007] If light enters an unintended area of ​​the projection lens in this way, the incident light may be shone as dazzling light for occupants of other vehicles or pedestrians.

[0008] On the other hand, vehicle headlights equipped with multiple light sources and multiple reflectors, as described above, aim to increase the brightness of the emitted light by using multiple light sources, and therefore require sufficient brightness of the light emitted outwards.

[0009] Therefore, the vehicle headlight of the present invention aims to suppress the generation of dazzling light while ensuring high brightness of the light emitted outwards. [Means for solving the problem]

[0010] The vehicle headlight according to the present invention comprises a plurality of light sources that each emit light, a plurality of reflectors that reflect the light emitted from the plurality of light sources and are arranged in a predetermined direction, a projection lens that projects the light reflected by the reflectors, and a light-shielding wall positioned between adjacent reflectors between the projection lens and the reflectors, wherein the light-shielding wall is composed of a first light-shielding portion and a second light-shielding portion positioned vertically, a first space is formed below the first light-shielding portion through which a portion of the light emitted from the light sources is transmitted, and a second space is formed above the second light-shielding portion through which a portion of the light emitted from the light sources is transmitted.

[0011] As a result, some of the light reflected by the reflectors is blocked by the light-shielding wall positioned between adjacent reflectors, while some of the light emitted from the light source is transmitted through the first and second spaces and irradiated outwards. [Effects of the Invention]

[0012] According to the present invention, a portion of the light reflected by the reflector is shielded by a light-shielding wall positioned between adjacent reflectors, and a portion of the light emitted from the light source is transmitted through the first and second spaces and irradiated outwards. As a result, the generation of dazzling light is suppressed, while ensuring high brightness of the light irradiated outwards. [Brief explanation of the drawing]

[0013] [Figure 1] Figures 2 to 8 illustrate embodiments of the vehicle headlight of the present invention, and this figure is a cross-sectional view of the vehicle headlight. [Figure 2] This is an exploded perspective view of the lamp unit with the projection lens omitted. [Figure 3] This is a perspective view of the lamp unit with the projection lens omitted. [Figure 4] This is a perspective view of a composite functional component. [Figure 5] This is a cross-sectional view showing the state in which a composite functional component is being molded using a mold. [Figure 6] This is a cross-sectional view showing the state after a composite functional component has been molded using a mold. [Figure 7] This is a perspective view showing the path of light emitted from a light source. [Figure 8] This is a perspective view showing the path of light emitted from a light source, etc., at a different angle than Figure 7. [Modes for carrying out the invention]

[0014] The embodiments for implementing the vehicle headlight of the present invention will be described below with reference to the attached drawings.

[0015] The following shows an example of a vehicle headlamp provided with three light sources and three reflectors. However, the vehicle headlamp of the present invention is not limited to a configuration provided with three light sources and three reflectors, and may be configured with two or more light sources and two or more reflectors.

[0016] The vehicle headlamp 1 includes a lamp housing 2 having an opening at the front end and a cover 3 closing the opening of the lamp housing 2 (see FIG. 1). The lamp housing 2 and the cover 3 constitute a lamp outer casing 4, and the space inside the lamp outer casing 4 is formed as a lamp chamber 5.

[0017] A lamp unit 6 is disposed inside the lamp outer casing 4. The lamp unit 6 has a heat sink 7, a composite functional member 8, a projection lens 9, and a substrate 10 (see FIGS. 1 to 3).

[0018] The heat sink 7 is integrally formed of a metal material with high heat dissipation, and has a base surface portion 11, a pair of connecting leg portions 12, a bridging portion 13, and a plurality of heat dissipation fin portions 14.

[0019] The base surface portion ı1 is formed in a plate shape facing in the vertical direction and is in a U-shaped form opened at the rear. From the front end portion of the base surface portion 11, a pair of mounting bosses 15 are provided in a state of protruding upward. The pair of mounting bosses 15 are spaced apart from each other left and right.

[0020] The pair of connecting leg portions 12 protrude downward from the left and right end portions at the front end portion of the base surface portion 11, respectively.

[0021] The bridging portion 13 is formed in a horizontally long plate shape, and the rear end portions at the left and right end portions are respectively continuous with the lower end portions of the connecting leg portions 12.

[0022] The heat dissipation fins 14 are arranged in a row facing left and right, and are positioned within the base surface 11. At least a portion of the front end of the heat dissipation fins 14 is continuous with the base surface 11, and the middle portion in the vertical direction is continuous with the base surface 11, so that the heat dissipation fins 14 have a portion located above the base surface 11 and a portion located below the base surface 11.

[0023] The composite functional member 8 is formed, for example, by injection molding using a mold, in which each part is integrally formed from a resin material. The composite functional member 8 has a mounting base 16, a lens holder 17, an upper forming wall 18, a pair of side walls 19, a lower forming wall 20, three reflectors 21, two first light-shielding parts 22, and two second light-shielding parts 23.

[0024] The mounting base 16 is formed in a plate shape oriented vertically and has a U-shape opening at the front. The mounting base 16 has a pair of mounting portions 24 located on both the left and right sides, and a rear side portion 25 whose left and right ends are continuous with the rear ends of the mounting portions 24. The mounting portions 24 have a boss insertion hole 24a that penetrates vertically. The space enclosed by the pair of mounting portions 24 and the rear side portion 25 in the mounting base 16 is formed as a light-passing hole 16a.

[0025] The lens holder 17 is formed in the shape of a horizontally elongated, roughly rectangular frame, with parts of both the left and right ends being continuous with the front ends of the mounting portion 24. Multiple first diffusion shapes 17a are formed on the inner circumferential surface of the lens holder 17, arranged in the circumferential direction. The first diffusion shapes 17a are, for example, semi-cylindrical shapes extending in the front-to-back direction, forming a shape similar to that of a cylindrical lens.

[0026] The upper forming wall 18 is continuous with the rear end of the upper surface of the lens holder 17 and is formed in a horizontally elongated plate shape. The upper forming wall 18 is formed in the same plane as, for example, the upper surface of the lens holder 17.

[0027] The side walls 19 are formed in a plate-like shape facing left and right, and are positioned spaced apart on the left and right sides. The upper end of the side wall 19 is continuous with both the left and right ends of the upper forming wall 18, and the front end is continuous with the side surface of the lens holder 17.

[0028] The lower forming wall 20 is formed, for example, in a plate shape with a portion bent, and both left and right ends are continuous with the rear portion of the lower end of the side wall 19. The lower forming wall 20 is located below the upper forming wall 18 and behind the upper forming wall 18.

[0029] The three reflectors 21 are arranged in a continuous line from left to right and are formed in a curved shape with openings facing forward and downward. The lower ends of the reflectors 21 are continuous with the opening edge of the light-passing hole 16a.

[0030] The two first light-shielding portions 22 are provided projecting downward from the upper forming wall 18 and are spaced apart to the left and right (see Figures 1 and 4). The first light-shielding portions 22 are formed in a plate shape that is oriented roughly in the left-right direction and becomes thinner as it goes downward, and are located in front of the boundary portion of adjacent reflectors 21.

[0031] Multiple second diffusion shapes 22a and multiple third diffusion shapes 22b are formed on one or both surfaces in the thickness direction of the first light-shielding portion 22. The second diffusion shapes 22a are formed, for example, as semi-cylindrical shapes extending vertically, similar to the shape of a cylindrical lens, and the third diffusion shapes 22b are formed, for example, as semi-cylindrical shapes extending front to back, similar to the shape of a cylindrical lens. The third diffusion shapes 22b are formed in front of the second diffusion shapes 22a. Note that there may be portions on both surfaces in the thickness direction of the first light-shielding portion 22 where neither the second diffusion shapes 22a nor the third diffusion shapes 22b are present.

[0032] The two second light-shielding portions 23 are provided projecting upward from the lower forming wall 20 and are positioned spaced apart to the left and right. The second light-shielding portions 23 are formed in a plate shape that faces approximately left and right and becomes thinner as it goes upward, and are positioned in front of the boundary portion of adjacent reflectors 21. The second light-shielding portions 23 are formed directly behind the first light-shielding portion 22 or slightly offset to the left or right of directly behind it. The front end of the second light-shielding portion 23 is located near the rear end of the first light-shielding portion 22, and a certain gap H is formed between the first light-shielding portion 22 and the second light-shielding portion 23 (see Figure 1). Note that the first light-shielding portion 22 and the second light-shielding portion 23 may be provided in a continuous state front and back or in contact front and back, and there may be no gap H.

[0033] In the lamp unit 6, a light-shielding wall 50 is formed by a first light-shielding portion 22 and a second light-shielding portion 23 (see Figures 1 and 4). In the light-shielding wall 50, for example, the lower end of the first light-shielding portion 22 is located below the upper end of the second light-shielding portion 23. A space is formed below the first light-shielding portion 22 and in front of the second light-shielding portion 23, and this space is formed as a first space 26 through which some light is transmitted. Also, a space is formed above the second light-shielding portion 23 and behind the first light-shielding portion 22, and this space is formed as a second space 27 through which some light is transmitted.

[0034] Multiple second diffusion shapes 23a are formed on both sides of the second light-shielding portion 23 in the thickness direction. The second diffusion shapes 23a are formed, for example, in the shape of semi-cylindrical shapes extending vertically, similar to the shape of a cylindrical lens. Note that there may be portions on both sides of the second light-shielding portion 23 in the thickness direction where the second diffusion shapes 23a are not present.

[0035] The projection lens 9 is held in the lens holder 17 of the composite functional member 8 (see Figure 1). The projection lens 9 has the function of controlling the incident light to emit parallel or nearly parallel light, and is held, for example, attached to the front surface of the lens holder 17.

[0036] The substrate 10 is formed in a horizontal shape and has mounting holes 10a at both the left and right ends (see Figure 2). Three light sources 28 are mounted on the upper surface of the substrate 10, spaced apart on the left and right. Light-emitting diodes (LEDs) are used as the light sources 28.

[0037] The three light sources 28 are designated as light source 28A, light source 28B, and light source 28C, in order from one side in the left-right direction. The light emitted from light sources 28A, 28B, and 28C respectively forms the low beam light distribution pattern. The light emitted from light sources 28A and 28C illuminates the entire area of ​​the low beam light distribution pattern, while the light emitted from light source 28B illuminates a portion of the central area of ​​the low beam light distribution pattern. Therefore, the low beam light distribution pattern is formed by the superposition of the light emitted from light sources 28A, 28B, and 28C.

[0038] The substrate 10 is placed on the base surface 11 of the heat sink 7 by inserting the mounting boss 15 from below into the mounting insertion hole 10a. With the substrate 10 placed on the base surface 11, the mounting boss 15 is also inserted from below into the boss insertion hole 24a formed in the mounting portion 24 of the composite functional member 8, and a part of the composite functional member 8 is placed on a part of the substrate 10. With the substrate 10 placed on the base surface 11 and a part of the composite functional member 8 placed on a part of the substrate 10, the substrate 10 and the composite functional member 8 are attached to the heat sink 7 by fastening the mounting screws 100 to the mounting boss 15 (see Figures 2 and 3).

[0039] When the substrate 10 and the composite functional component 8 are attached to the heat sink 7, the three light sources 28 are each positioned directly below the three reflectors 21.

[0040] In the vehicle headlight 1 configured as described above, the composite functional member 8 is formed by injection molding using a mold (see Figures 5 and 6).

[0041] For example, a first mold 60, a second mold 70, and a third mold 80 are used as molds for molding the composite functional member 8. The first mold 60 moves in the front-to-back direction during molding, while the second mold 70 and the third mold 80 move in the up-and-down direction during molding.

[0042] The first mold 60 is moved backward relative to its pre-molding reference position, the second mold 70 is moved downward relative to its pre-molding reference position, and the third mold 80 is moved upward relative to its pre-molding reference position, causing them to abut against each other to form a cavity, into which the cavity is then filled with molten resin 90 (see Figure 5).

[0043] As the molten resin 90 cools, the first mold 60 moves forward, the second mold 70 moves upward, and the third mold 80 moves downward to form the composite functional member 8 (see Figure 6). At this time, for example, the first semi-cylindrical diffusion shape 17a extending in front of and behind the lens holder 17 and the third semi-cylindrical diffusion shape 22b extending in front of and behind the first light-shielding portion 22 are formed by the first mold 60, the second semi-cylindrical diffusion shape 22a extending above and below the first light-shielding portion 22 is formed by the third mold 80, and the second semi-cylindrical diffusion shape 23a extending above and below the second light-shielding portion 23 is formed by the second mold 70.

[0044] As described above, in the vehicle headlight 1, the lens holder 17, the multiple reflectors 21, and the multiple light-shielding walls 50 are integrally formed by injection molding using a mold.

[0045] Therefore, since the lens holder 17, reflector 21, and light-shielding wall 50 are formed as a single component, the number of parts can be reduced, and the relative positional accuracy of the projection lens 9, reflector 21, and light-shielding wall 50 can be improved, allowing for the formation of an appropriate light distribution pattern by the light emitted from the light source 28.

[0046] Furthermore, as described above, the first light-shielding portion 22 and the second light-shielding portion 23 are formed in a plate shape, with the thickness of the first light-shielding portion 22 decreasing as it goes downwards, and the thickness of the second light-shielding portion 23 decreasing as it goes upwards.

[0047] Therefore, by using a second mold 70 and a third mold 80 in the molding of the light-shielding wall 50 and setting their release directions to opposite directions, it becomes possible to form the first light-shielding portion 22 and the second light-shielding portion 23, and the light-shielding wall 50 can be easily molded.

[0048] In the vehicle headlight 1 configured as described above, light is emitted simultaneously from light sources 28A, 28B, and 28C. The light emitted from light sources 28A, 28B, and 28C is reflected and controlled by their respective reflectors 21 and directed towards the projection lens 9. The projection lens 9 controls the light to be parallel or nearly parallel, which is then transmitted through the cover 3 and directed outwards as light for the headlamp.

[0049] At this time, some of the light P emitted from light sources 28A, 28B, and 28C reaches the first light-shielding section 22 or the second light-shielding section 23 and is shielded by the first light-shielding section 22 or the second light-shielding section 23 (see Figure 7). For simplicity of explanation, Figure 7 shows only the light P emitted from light sources 28A and 28B. In particular, the light P is diffused by the second diffusion shape 22a, the third diffusion shape 22b, and the second diffusion shape 23a formed in the first light-shielding section 22 and the second light-shielding section 23, respectively, so as not to enter the projection lens 9 and thus light shielding is performed.

[0050] On the other hand, some of the light Q emitted from light sources 28A, 28B, and 28C passes through the first space 26 below the first light-shielding portion 22 and the second space 27 above the second light-shielding portion 23, or through the gap H between the first light-shielding portion 22 and the second light-shielding portion 23, and is transmitted through the projection lens 9 and the cover 3 and irradiated outwards (see Figures 7 and 8). For simplicity of explanation, Figure 7 shows only the light Q emitted from light sources 28A and 28B, and Figure 8 shows only the light Q emitted from light source 28A. Light Q is part of the light that forms the light distribution pattern of the headlamp, and is reflected by various parts of the lamp unit 6 and incident on the projection lens 9.

[0051] In this way, in the vehicle headlight 1, the light P is shielded by the first light-shielding portion 22 or the second light-shielding portion 23, making it difficult for unnecessary patterns of glare to form outside the light distribution pattern of the headlamp. In addition, the presence of light Q makes it difficult for problems such as insufficient light intensity in the light distribution pattern of the headlamp to occur, and suppresses a decrease in light distribution performance. Therefore, the presence of light P and light Q suppresses the generation of glare and a decrease in light distribution performance, resulting in the formation of a good light distribution pattern for the headlamp.

[0052] Furthermore, in the composite functional member 8, it is also possible to form a light-shielding section in the area where the first space 26 and the second space 27 exist, so that the light-shielding wall 50 consists of a single plate-shaped light-shielding section. However, in this case, since both light P and light Q are shielded by the light-shielding section, the generation of dazzling light is suppressed, but insufficient light intensity occurs in the light distribution pattern of the headlamp.

[0053] Therefore, by configuring the light-shielding wall 50 with a first light-shielding portion 22 and a second light-shielding portion 23 so that a first space 26 and a second space 27 are formed, it is possible to suppress the generation of dazzling light and achieve the formation of a good light distribution pattern of the headlamp without causing insufficient light intensity.

[0054] Furthermore, some of the light R emitted from light sources 28A, 28B, and 28C reaches the first diffusion shape 17a of the lens holder 17 (see Figure 7). The light R that reaches the first diffusion shape 17a is diffused by the first diffusion shape 17a and does not enter the projection lens 9, thus providing light shielding.

[0055] As described above, in the vehicle headlight 1, the light-shielding wall 50 is composed of a first light-shielding portion 22 and a second light-shielding portion 23 positioned vertically. A first space 26 is formed below the first light-shielding portion 22 through which a portion of the light emitted from the light source 28 is transmitted, and a second space 27 is formed above the second light-shielding portion 23 through which a portion of the light emitted from the light source 28 is transmitted.

[0056] Therefore, a portion of the light reflected by the reflector 21 is shielded by the light-shielding wall 50 located between adjacent reflectors 21, and a portion of the light emitted from the light source 28 is transmitted through the first space 26 and the second space 27 and irradiated outwards. As a result, the generation of dazzling light is suppressed, while ensuring high brightness of the light irradiated outwards.

[0057] Furthermore, since the first light-shielding portion 22 and the second light-shielding portion 23 are positioned at a distance from each other in the front-rear direction, and the first light-shielding portion 22 and the second light-shielding portion 23 are provided at different positions in the front-rear direction, the molding accuracy of the first light-shielding portion 22 and the second light-shielding portion 23 is increased, and an appropriate control state for the light emitted from the light source 28 can be ensured.

[0058] Furthermore, since diffusion shapes (second diffusion shape 22a, third diffusion shape 22b, and second diffusion shape 23a) are formed on at least one surface in the thickness direction of the light-shielding wall 50 (each surface of the first light-shielding portion 22 and each surface of the second light-shielding portion 23), the light that reaches the light-shielding wall 50 is diffused by the diffusion shapes, thereby improving the light-shielding performance. [Explanation of Symbols]

[0059] 1. Vehicle headlights 9. Projection lens 17 Lens holder 21 Reflector 22 First light-shielding part 22a Second diffusion shape 22b Third diffusion shape 23 Second light-shielding section 23a Second diffusion shape 26 The first space 27 The Second Space 50 Light-blocking wall 60 First mold 70 Second mold 80 Third mold

Claims

1. Multiple light sources, each emitting light, Multiple reflectors that reflect light emitted from multiple light sources and are arranged in a predetermined direction, A projection lens that projects the light reflected by the reflector, The projected lens and the reflector are further comprising a light-shielding wall positioned between adjacent reflectors, The light-shielding wall is composed of a first light-shielding portion and a second light-shielding portion positioned vertically. A first space is formed below the first light-shielding portion, through which a portion of the light emitted from the light source is transmitted, and a second space is formed above the second light-shielding portion, through which a portion of the light emitted from the light source is transmitted. Vehicle headlights.

2. The first light-shielding portion and the second light-shielding portion are positioned separated in the front-rear direction. The vehicle headlight according to claim 1.

3. A lens holder is provided to hold the projection lens. The lens holder, the plurality of reflectors, and the plurality of light-shielding walls are integrally formed by injection molding using a mold. The vehicle headlight according to claim 2.

4. The first light-shielding portion and the second light-shielding portion are formed in the shape of plates, The thickness of the first light-shielding portion is made thinner as it goes downwards. The thickness of the second light-shielding portion is made thinner as it goes upwards. The vehicle headlight according to claim 3.

5. A diffusion shape is formed on at least one surface in the thickness direction of the light-shielding wall. A vehicle headlight according to claim 1, claim 2, claim 3, or claim 4.

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