Lens components and light source modules

Abstract

A lens component (1) has: a front surface (10); an outer side surface (20); a rear protruding surface (30); and an inner side surface (40). The front surface (10) has a central protruding portion (12) and an annular flat portion (14). The rear protruding surface (30) guides, to the central protruding portion (12), light that has exited a light source (51) and entered the rear protruding surface (30). The central protruding portion (12) outputs the light having entered the central protruding portion (12), forward, as parallel beams. The outer side surface (20) totally reflects light that has exited the light source (51) and entered the inner side surface (40), to the annular flat portion (14), as parallel beams. All the regions of the front surface (10) emit light.

Description

[Technical field]

[0001] The present invention relates to a lens component and a light source module used in vehicle lamps and the like. [Background technology]

[0002] A lens component described in Patent Document 1 is known. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japan Special Publication No. 2002-505759 Summary of the Invention [Problem to be solved by the invention]

[0004] The lens component described in Patent Document 1 cannot emit light from the entire area of ​​the front surface of the lens component, and is therefore unsuitable for use as a vehicle lamp. An object of the present invention is to provide a lens component and a light source module suitable for use in vehicle lamps. [Means for solving the problem]

[0005] A lens component according to one aspect of the present invention comprises: A lens component used in a vehicle lamp that emits light forward, With a front facing forward, An outer surface that curves and extends from the rear toward the front surface; a rear convex surface that is provided at a position recessed forward from the outer surface in a region through which an axis line that passes through the light source and is parallel to the direction in which the light is emitted passes, and that is convex toward the rear; an inner surface connecting a rear end portion of the outer surface and the rear convex surface; a cavity that is open to the rear is formed by the rear convex surface and the inner surface, The front surface has a central convex portion that is provided in a region through which the axis passes and has a forwardly convex shape, and an annular flat portion that is continuous with an outer edge of the central convex portion, extends flat in a direction perpendicular to the axis, and is provided annularly on the outer edge of the central convex portion, the rear convex surface is shaped to guide light emitted from a light source disposed in the cavity and incident on the rear convex surface to the central convex portion, the central convex portion is shaped to emit light incident on the central convex portion forward as parallel light, the outer surface is shaped to totally reflect light emitted from the light source and incident on the inner surface so as to guide the light as parallel light to the front surface other than the central convex portion, The entire area of ​​the front surface is illuminated.

[0006] According to the present invention, it is possible to provide a lens component and a light source module suitable for a vehicle lamp. [Brief description of the drawings]

[0007] [Figure 1] 1 is a cross-sectional view of a lens component according to an embodiment of the present invention. [Diagram 2] FIG. [Diagram 3] FIG. 11 is a cross-sectional view showing a lens component of a reference example. [Figure 4] 1 is a cross-sectional view of a light source module according to an embodiment of the present invention. [Diagram 5] FIG. 5 is a perspective view of the light source module shown in FIG. [Figure 6] FIG. 13 is a perspective view of a light source module according to a modified example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] The present invention will be described below with reference to the drawings based on the embodiments. The same or equivalent components, parts, and processes shown in each drawing are given the same reference numerals, and duplicated descriptions are omitted as appropriate. In addition, the embodiments are not intended to limit the invention, but are merely examples, and all features and combinations thereof described in the embodiments are not necessarily essential to the invention.

[0009] Fig. 1 is a cross-sectional view of a lens component 1 and a light source 51 according to an embodiment of the present invention. Fig. 2 is a front view of the lens component 1. The lens component 1 is used, for example, in a vehicle lamp such as a vehicle headlamp that emits light forward from the vehicle.

[0010] 1 and 2, the lens component 1 has a front surface 10, an outer surface 20, a rear convex surface 30, and an inner surface 40. In a side view, the lens component 1 has a generally truncated cone shape with a diameter decreasing from the front to the rear. For convenience in the following description, the direction in which the lens component 1 emits light is defined as the front. In FIG. 1, the left side is the front.

[0011] The front surface 10 is a circular surface facing forward of the lens component 1. The front surface 10 has a central convex portion 12 provided in the center, and an annular flat portion 14 provided on the outer side of this central convex portion 12.

[0012] The central convex portion 12 is provided in an area centered on a point on the front surface 10 through which an axis Ax passes, the axis Ax passing through the light source 51 and parallel to the direction in which the light from the light source 51 is emitted. The central convex portion 12 is formed so as to be convex toward the front, as shown in Fig. 1. The central convex portion 12 is also formed so as to be elliptical when viewed from the front, as shown in Fig. 2. Fig. 1 is a cross-sectional view taken along line AA in Fig. 2.

[0013] The annular flat portion 14 is provided so as to continue from the outer edge of the central protrusion 12 and extend flatly in a direction perpendicular to the direction of the axis Ax. The annular flat portion 14 is provided in an annular shape on the outer edge of the central protrusion 12.

[0014] In this embodiment, as shown in Fig. 2, a diffusion section 15 consisting of a plurality of grooves is formed on the front surface 10. The diffusion section 15 diffuses the light emitted from the light source 51 in the long axis direction of the central convex portion 12 and emits it. The diffusion section 15 is formed on both ends of the front surface 10 in the long axis direction of the elliptical central convex portion 12 (left-right direction in Fig. 2). The grooves of the diffusion section 15 extend in the short axis direction of the elliptical central convex portion 12 (up-down direction in Fig. 2). The diffusion section 15 is formed, for example, by subjecting the annular flat portion 14 to fine uneven processing such as knurling.

[0015] In the example shown in Fig. 2, the diffusion portion 15 is formed at an end portion on the outer side of the central convex portion 12 in the long axis direction of the central convex portion 12, but is not limited thereto. The diffusion portion 15 may be formed, for example, on the inner side of both ends of the central convex portion 12 in the long axis direction of the central convex portion 12. In this case, the shape of the annular flat portion is a C-shape or a ring having a part cut out, but even in such a shape, the part that continues from the outer edge of the central convex portion 12 and extends flatly in a direction perpendicular to the axis Ax is called the annular flat portion 14. The term "annular" here includes shapes such as a C-shape and one or more arcs.

[0016] Returning to FIG. 1 , the outer surface 20 is provided so as to extend in a curved manner from the rear to the front of the lens component 1. The outer surface 20 is configured as a curved surface that is rotationally symmetrical about the axis line Ax. The front side of the outer surface 20 is provided so as to connect to the outer circumferential edge of the front surface 10. The rear side of the outer surface 20 is provided so as to connect to the inner surface 40, which will be described later.

[0017] The rear convex surface 30 is provided at a position recessed forward from the rear end of the outer surface 20. The rear convex surface 30 is provided in an area centered on a point through which the axis Ax passes. The rear convex surface 30 is provided so as to be located rearward of the central convex portion 12 of the front surface 10. The rear convex surface 30 is formed so as to be convex toward the rear. When viewed from the rear, the rear convex surface 30 is formed in an elliptical shape corresponding to the shape of the central convex portion 12 of the front surface 10. The length of the major axis (major axis) of the elliptical rear convex surface 30 is set to be shorter than the major axis of the elliptical central convex portion 12. In addition, the length of the minor axis (minor axis) of the rear convex surface 30 is set to be shorter than the minor axis of the central convex portion 12. Incidentally, the light proceeding from the rear convex surface 30 toward the central convex portion 12 propagates in a divergent manner within the lens component 1. For this reason, the central convex portion 12 has a shape that converts the light propagating in such a divergent manner into parallel light parallel to the axis Ax.

[0018] The inner surface 40 is provided so as to connect between the outer surface 20 and the rear convex surface 30. The rear side of the inner surface 40 is provided so as to connect to the rear end of the outer surface 20. The front side of the inner surface 40 is provided so as to connect to the outer periphery of the rear convex surface 30. The shape of the inner surface 40 is designed so that light traveling from the inner surface 40 toward the annular flat portion 14 becomes parallel light that is parallel to the axis Ax.

[0019] A cavity 45 that opens toward the rear is formed at the rear of the lens component 1 by the rear convex surface 30 and the inner surface 40. When viewed from behind, the cavity 45 is formed in an elliptical shape, which is the same shape as the above-mentioned rear convex surface 30. The light source 51 is disposed at the rear of the lens component 1 so as to face this cavity 45.

[0020] Next, the function of each part that guides the light emitted from the light source 51 to the front of the lens component 1 will be described. First, light X1 emitted from the light source 51 toward the front direction (direction of axis Ax) is incident on the rear convex surface 30. The light X1 incident on the rear convex surface 30 is refracted so as to be incident on the central convex portion 12. Specifically, light incident on the center of the rear convex surface 30 is guided to the center of the central convex portion 12. Light incident on the outer periphery of the rear convex surface 30 is guided to the outer periphery of the central convex portion 12. Light X2 incident on the outer edge of the rear convex surface 30 is guided to the outer edge of the central convex portion 12 (boundary portion 13 between the central convex portion 12 and the annular flat portion 14). The light X1 incident on the central convex portion 12 is emitted forward as parallel light.

[0021] Of the light emitted from the light source 51, light X3 emitted laterally (in other words, at an angle equal to or greater than a predetermined angle from the front direction) is incident on the inner surface 40. The light X3 incident on the inner surface 40 is refracted in a direction away from the axis Ax and is incident on the outer surface 20. The light X3 incident on the outer surface 20 is totally reflected by the outer surface 20 as parallel light and is guided to the front surface 10 (annular flat portion 14 and diffusing portion 15) other than the central convex portion 12. The light X3 incident on the annular flat portion 14 is emitted directly to the front of the lens component 100 as parallel light. The light incident on the diffusing portion 15 is diffused in the left-right direction and emitted forward.

[0022] Thus, in lens component 1 of the present embodiment, light is emitted from the entire surface of front surface 10 of lens component 1, including boundary portion 13 between central convex portion 12 and annular flat portion 14. In other words, lens component 1 illuminates from the entire area of ​​front surface 10, making it suitable as a lens component for use in vehicle lamps.

[0023] FIG. 3 is a diagram showing a lens component 100 described in Patent Document 1 according to a reference example. Unlike the above embodiment, the lens component described in Patent Document 1 cannot emit light from the entire area of ​​the front surface of the lens component 100. As shown in FIG. 3, light Y1 emitted forward from the light source 101 and incident on a surface 104 facing the light source 101 is refracted by this surface 104, enters a lens portion 105 recessed from a flat portion 103 on the front surface of the lens component 100, and is emitted as parallel light parallel to the axis Ax. Light Y2 emitted laterally from the light source 101 and totally reflected by the outer surface 102 enters the flat portion 103 on the front surface, and is emitted as parallel light parallel to the axis Ax. In this way, the lens portion 105 and the flat portion 103 emit light. However, light is not incident on the inclined portion 106 between the lens portion 105 and the flat portion 103, and the inclined portion 106 does not emit light. For this reason, when lens component 100 is viewed from the front, it appears that a doughnut-shaped dark portion occurs at the boundary between lens portion 105 and flat portion 103, which corresponds to inclined portion . Along with the demand for smaller vehicle lamps, there is also a demand for smaller lens components. In order to meet such demands, it is preferable to ensure a large amount of emitted light in a limited emission area. The lens components of Patent Document 1 have localized dark areas and cannot accommodate the miniaturization of lens components.

[0024] In contrast, according to the lens component 1 of this embodiment, a central convex portion 12 and an annular flat portion 14 are provided on the front surface 10 of the lens component 1, and the two are continuous. The lens component 1 of this embodiment is configured so that light incident on the outer edge of the rear convex surface 30 from the light source 51 is guided to the boundary portion 13 between the central convex portion 12 and the annular flat portion 14. Therefore, the boundary portion 13 between the central convex portion 12 and the annular flat portion 14 can also be illuminated, and the entire area of ​​the front surface 10 can be illuminated without generating dark areas. Therefore, the lens component 1 of this embodiment is suitable for vehicle lamps that require miniaturization. In particular, the lens component 1 of this embodiment is suitable for vehicle lamps such as headlamps, cornering lamps, and fog lamps.

[0025] 2, in lens component 1 of this embodiment, central convex portion 12 has an elliptical shape when viewed from the front, so that light can be emitted widely in the major axis direction. For this reason, lens component 1 is suitable for vehicle lamps that are desired to form a wide light distribution pattern in the left-right direction in front of the vehicle.

[0026] Furthermore, in lens component 1 of the present embodiment, diffusion portion 15 consisting of a plurality of grooves is formed at the end of annular flat portion 14 in the major axis direction of elliptical central convex portion 12. This makes it possible to further widen the light irradiation range in the major axis direction of central convex portion 12 on front surface 10.

[0027] Next, a light source module 50 using the lens component 1 of the above-described embodiment will be described. Fig. 4 is a cross-sectional view of the light source module 50. Fig. 5 is a perspective view of the light source module 50. As shown in Figs. 4 and 5, the light source module 50 includes a lens component 1, a light source 51, a substrate 52, a lens holder 53, and a heat sink 55.

[0028] The light source 51 is configured by a semiconductor light source such as an LED (Light Emitting Diode) or an LD (Laser Diode). The light source 51 is mounted on a substrate 52. The substrate 52 is attached to a lens holder 53. The light source 51 mounted on the substrate 52 is disposed so as to face the cavity 45 of the lens component 1.

[0029] Lens holder 53 is attached to heat sink 55. Lens holder 53 is provided with substrate support stand 57 and mounting stand 56. Lens holder 53 is a substantially plate-shaped member. Substrate support stand 57 and mounting stand 56 are provided on one surface of lens holder 53. Heat sink 55 is provided on the other surface of lens holder 53.

[0030] As shown in FIG. 5, the lens component 1 has a pair of straight line portions 16 and an arc portion 17 connecting the pair of straight line portions 16. When the lens component 1 is viewed from the front, the pair of straight line portions 16 are provided on the outer edge of the annular flat portion 14 so as to face each other across the axis Ax. The straight line portions 16 are formed on the outer edge of the annular flat portion 14 in the minor axis direction of the elliptical central convex portion 12 (the up-down direction in FIG. 5). The arc portion 17 is formed on the outer edge of the annular flat portion 14 in the major axis direction of the elliptical central convex portion 12 (the left-right direction in FIG. 5). When viewed from the front, the lens component 1 is formed in the shape of a rectangle with rounded corners.

[0031] The lens component 1 shown in FIG. 5 has an attachment portion 18. The attachment portion 18 is a portion for attaching the lens component 1 to the lens holder 53. The attachment portion 18 extends from the straight portion 16 in a direction away from the axis Ax when the lens component 1 is viewed from the front. The attachment portion 18 is an L-shaped portion. The attachment portion 18 extends from the straight portion 16 toward the lens holder 53, and extends in a direction away from the axis Ax at its extended end. The lens holder 53 is attached to this attachment portion 18. In the illustrated example, a screw 54 inserted into a screw hole 19 (see FIG. 4) provided in the attachment portion 18 is screwed into an attachment base 56 of the lens holder 53, thereby attaching the lens component 1 to the lens holder 53.

[0032] Meanwhile, vehicle lamps are required to have a good appearance design, and a lens component with a long and narrow shape extending in the left-right direction when viewed from the front is preferred because it gives a sharp impression to the viewer. On the other hand, the lens component 1 used in vehicle lamps is required to have the property of irradiating light widely in the long axis direction of the central convex portion 12. The light source module 50 of this embodiment has straight sections 16 at the top and bottom when viewed from the front, making it easy to design a vehicle lamp that looks good. In addition, the straight section 16, which is designed to cut out a part of the annular flat section 14, is provided at the end in the minor axis direction of the elliptical central convex section 12. This makes it easy to form the annular flat section 14 large in the major axis direction, making it easy to irradiate light widely in the major axis direction. Furthermore, if mounting portion 18 is provided on lens component 1, light that enters mounting portion 18 cannot be effectively emitted forward. However, in lens component 1 of the present embodiment, mounting portion 18 is provided at the top and bottom when lens component 1 is viewed from the front. As described above, lens component 1 is required to have a wide illumination range in the left-right direction, but not so wide an illumination range in the up-down direction. For this reason, even if light that has entered mounting portions 18 provided at the top and bottom cannot be illuminated forward, it is unlikely to have a significant effect on the light distribution pattern formed by the vehicle lamp, and light source module 50 of the present embodiment is suitable for vehicle lamps.

[0033] Next, a modification of the light source module will be described. Fig. 6 is a perspective view of a light source module 60 according to a modified example. As shown in Fig. 6, the light source module 60 includes an optical sensor 61 in addition to the configuration of the light source module 50 described above.

[0034] The optical sensor 61 is attached near the straight portion 16 formed on the outer edge of the annular flat portion 14 on the front surface 10 of the lens component 1 having a rounded rectangular shape. The optical sensor 61 is a sensor capable of detecting light of a specific wavelength from the light source 51 emitted from the straight portion 16 to the outside of the lens component 1. The light source 51 has a light emitting portion (light emitting chip) and a phosphor provided to cover the light emitting chip.

[0035] According to the light source module 60 of the above modification, for example, if the phosphor covering the light emitting chip of the light source 51 becomes detached, the light (e.g., ultraviolet light) directly emitted from the light emitting chip can be detected by the optical sensor 61. Therefore, by turning off the emission of the light source 51 when unintended light such as ultraviolet light is detected as emitted light from the lens component 1, it is possible to prevent such light from leaking to the outside from the lens component 1. In the lens component 1 shown in FIG. 6, the attachment portion 18 is provided on the arc portion 17.

[0036] The present invention is not limited to the above-described embodiment, and can be freely modified, improved, etc. as appropriate. The material, shape, size, numerical value, form, number, location, etc. of each component in the above-described embodiment are arbitrary and not limited as long as the present invention can be achieved.

[0037] This application is based on a Japanese patent application (Patent Application No. 2019-186786) filed on October 10, 2019, the contents of which are incorporated herein by reference. [Industrial Applicability]

[0038] According to the present invention, it is possible to provide a lens component and a light source module suitable for a vehicle lamp.

Claims

1. A lens component used in a vehicle lamp that emits light forward, With a front facing forward, An outer surface that curves and extends from the rear toward the front surface; a rear convex surface that is provided at a position recessed forward from the outer surface in a region through which an axis line that passes through the light source and is parallel to the direction in which the light is emitted passes, and that is convex toward the rear; an inner surface connecting a rear end portion of the outer surface and the rear convex surface; a cavity that is open to the rear is formed by the rear convex surface and the inner surface, The front surface has a central convex portion that is provided in a region through which the axis passes and has a forwardly convex shape, and an annular flat portion that is continuous with an outer edge of the central convex portion, extends flat in a direction perpendicular to the axis, and is provided annularly on the outer edge of the central convex portion, the rear convex surface is shaped to guide light emitted from a light source disposed in the cavity and incident on the rear convex surface to the central convex portion, the central convex portion is shaped to emit light incident on the central convex portion forward as parallel light, the outer surface is shaped to totally reflect light emitted from the light source and incident on the inner surface so as to guide the light as parallel light to the front surface other than the central convex portion, all areas of said front surface are luminous; A lens component, wherein light incident on the boundary between the rear convex surface and the inner surface exits from the boundary between the central convex portion and the annular flat portion.

2. The lens component according to claim 1 , wherein the central convex portion has an elliptical shape when the lens component is viewed from the front.

3. The lens component according to claim 1 , wherein the front surface is provided with a diffusion portion formed of a plurality of grooves.

4. the central convex portion is elliptical when the lens component is viewed from the front, The front surface is provided with a diffusion portion formed of a plurality of grooves, The lens component according to claim 1 , wherein the diffusion portion is provided at an end of the front surface in the direction of a major axis of the elliptical central convex portion.

5. The lens component according to any one of claims 1 to 4; a semiconductor light source disposed in the cavity of the lens component.

6. The lens component is attached to a lens holder; When the lens component is viewed from the front, an outer edge of the annular flat portion is a rounded rectangle having a pair of straight line portions facing each other across the axis and an arc portion connecting the straight line portions, a mounting portion is provided extending from the straight portion in a direction away from the axis when the lens component is viewed from the front, The light source module according to claim 5 , wherein the lens holder is attached to the mounting portion.

7. When the lens component is viewed from the front, an outer edge of the annular flat portion is a rounded rectangle having a pair of straight line portions facing each other across the axis and an arc portion connecting the straight line portions, an optical sensor is provided on the straight portion to detect light leaking from the straight portion to the outside; The light source module according to claim 5 , wherein the optical sensor detects light emitted when a phosphor of the semiconductor light source is removed.

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