Lighting unit

Abstract

To prevent the rotation of a reflector which occurs when assembly, in a lamp fitting unit having a light source substrate jointly fastened with the reflector.SOLUTION: A lamp fitting unit (100) comprises a light source substrate (40) mounted with a light source (42), a reflector (30) reflecting the light of the light source, and a fixing portion (50) to which the light source substrate and the reflector are fixed, wherein the light source substrate (40) is held between the reflector (30) and the fixing portion (50), the reflector (30) is positioned with respect to the light source substrate (40) by a positioning portion (34), and fixed to the fixing portion (50) by fastening portions (36) on both longitudinal sides of the reflector, the reflector (30) has a rotation suppressing portion (38) protruding in a direction in which the fixing portion (50) exists, the rotation suppressing portion (38) is formed beyond the positioning portion (34).SELECTED DRAWING: Figure 7

Description

[Technical Field]

[0001] The present invention relates to a lamp unit used in a vehicle such as an automobile, and more particularly to a lamp unit in which a light source and a reflector are fixed in close proximity to each other. [Background technology]

[0002] For recent ADB (Adaptive Driving Beam) technology, there is a lighting unit in which multiple light sources are mounted two-dimensionally on a substrate and the light sources and reflector are arranged closely together. Such a lighting unit can be configured to include a light source substrate, a reflector, and a fixing part for these, with the reflector positioned relative to the light source substrate, the light source substrate sandwiched between the reflector and the fixing part, both longitudinal sides of the reflector fixed, and the light source substrate fastened together with the reflector (for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-46714 Summary of the Invention [Problem to be solved by the invention]

[0004] However, with this configuration, when assembling both sides of the reflector to the fixing parts, if one side is fixed, the longitudinal direction of the reflector will rotate and tilt, and there is a risk that the reflector will be assembled in an incorrect positional relationship in the fore-and-aft direction of the lighting unit.

[0005] The present invention has been proposed to solve the above-mentioned problems, and aims to prevent rotation of a reflector during assembly in a lighting unit in which a light source board is fastened together with a reflector. [Means for solving the problem]

[0006] In order to solve the above problems, a lighting unit according to one aspect of the present invention includes a light source board on which a light source is mounted, a reflector that reflects light from the light source, and a fixing portion to which the light source board and the reflector are fixed, the light source board is sandwiched between the reflector and the fixing portion, the reflector is positioned relative to the light source board by a positioning portion for the light source board, and the reflector is fastened to the fixing portion by fastening portions on both sides in the longitudinal direction of the reflector. By screw The reflector is fixed, and the reflector has a protruding rotation suppressing portion in a direction of the fixing portion, and the rotation suppressing portion is formed outside the positioning portion. When the reflector is not fixed to the fixing portion, the fixing portion is not in contact with the fixing portion, and when the reflector is fixed by the screw, the fixing portion prevents the fixing portion from sinking, thereby suppressing rotation of the reflector. It is characterized by the following.

[0007] In the above aspect, it is also preferable that the rotation suppressing portion is formed coaxially with a fastening axis that connects the fastening portions on both sides in the longitudinal direction.

[0008] In the above aspect, it is also preferable that the rotation suppressing portion is formed in a surface shape that includes the fastening shaft as a part thereof.

[0009] In the above aspect, it is also preferable that at least one of the rotation suppressing portions be formed on one of both sides in the longitudinal direction that is fastened first in the manufacturing process.

[0010] In the above aspect, it is also preferable that the rotation suppressing portion is formed on the outermost side of the reflector. [Effects of the Invention]

[0011] According to the present invention, in a lighting unit in which a light source board is fastened together with a reflector, rotation of the reflector during assembly can be prevented. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a front perspective view of a lamp unit 100 according to a first embodiment. [Figure 2] FIG. 2 is an exploded perspective view of the lamp unit 100. [Figure 3]1 is a front view of a heat sink 50 according to a first embodiment. [Figure 4] FIG. 2 is a rear view of the reflector 30 according to the first embodiment. [Figure 5] FIG. 2 is a perspective view for explaining how three elements are assembled in the first embodiment. [Figure 6] FIG. 10 is a schematic end view illustrating the assembly of the three elements when a rotation suppressing portion 38 is not formed. [Figure 7] FIG. 3 is a cross-sectional view illustrating the assembly of three elements in the first embodiment. [Figure 8] FIG. 8 is an enlarged cross-sectional view of a main part of FIG. 7. [Figure 9] FIG. 10 is a rear view of a reflector 30 according to a second embodiment. [Figure 10] FIG. 10 is a rear view of a reflector 30 according to a third embodiment. [Figure 11] FIG. 10 is a front view of a heat sink 50 according to a fourth embodiment. [Figure 12] FIG. 10 is an enlarged cross-sectional view of a main part showing an assembly state in the fourth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0013] The present invention will be described below with reference to the drawings based on preferred embodiments. The same or equivalent components, members, and processes shown in each drawing are designated by the same reference numerals, and redundant descriptions will be omitted where appropriate. Furthermore, the embodiments are merely examples and do not limit the invention, and all features and combinations described in the embodiments are not necessarily essential to the invention. Furthermore, when terms indicating directions, such as "upper," "lower," "front," "rear," "left," "right," "inner," "outer," "front," "back," "front," and "rear," are used in this specification, they refer to the directions in the position of the lamp unit when mounted on a vehicle.

[0014] 1. First embodiment 1-1. Overall structure Fig. 1 is a front perspective view of a lamp unit 100 according to a first embodiment, and Fig. 2 is an exploded perspective view of the lamp unit 100. The lamp unit 100 is, for example, a headlamp mounted on the right front of a vehicle. The lamp unit 100 includes a lens 10, a lens holder 20, a reflector 30, a light source substrate 40, a heat sink 50, and a cooling fan 60.

[0015] The lens 10 is made of a light-transmitting material and irradiates light from a light source (described later) mounted on the light source substrate 40 forward so as to achieve a predetermined light distribution. The lens holder 20 is a member for holding the lens 10 and is fixed to a heat sink 50. The reflector 30 has abutment portions 311 and 312 on both the left and right sides for contacting the heat sink 50. The front side of the reflector 30 has, between the abutment portions 311 and 312, a first reflecting portion 321 and a pair of second reflecting portions 322 that reflect a portion of the light from the light source toward the lens 10. The configuration of the back side of the reflector 30 will be described later with reference to FIG. 4.

[0016] As shown in FIG. 2, the light source substrate 40 has an LED array 42 on its surface (in this embodiment, the LED array 42 is the "light source" in the claims). The LED array 42 has a plurality of LEDs (light-emitting elements) for low-beam light distribution and ADB light distribution. In this embodiment, the LEDs are arranged in two rows, one above the other and one to the left and right, with the upper row responsible for low-beam light distribution and the lower row responsible for ADB light distribution. The area in which the LED array 42 and its wiring pattern are formed is designated by the reference numeral 43 as a lighting control area. Notches 45 are formed on the left and right end surfaces of the light source substrate 40, respectively, for positioning the light source substrate 40 and the heat sink 50.

[0017] The heat sink 50 is made of a material with good thermal conductivity, such as die-cast aluminum, and is in contact with the rear surface of the light source substrate 40, dissipating heat generated by the light emission of the LED array 42 into the air. The light source substrate 40 and the reflector 30 are fixed to the heat sink 50. Details of this configuration will be described later with reference to FIG. 3. The cooling fan 60 is disposed behind the heat sink 50, and cools the heat from the heat sink 50 by blowing air.

[0018] 1-2. Heat sink 50 configuration 3 is a front view of the heat sink 50 according to the first embodiment. The front side of the heat sink 50 has fixing surfaces 511, 512, 513, and 514 arranged in the outer circumferential direction, and inside thereof has a substrate accommodating portion 52. The lens holder 20 having the lens 10 attached thereto, the reflector 30, and the light source substrate 40 are fixed to the heat sink 50.

[0019] The substrate accommodating portion 52 is inclined forward and backward so that the lower side is more forward than the upper side, and is designed to accommodate the light source substrate 40 (see also FIG. 2). The substrate accommodating portion 52 is provided with a semicircular protrusion 53 for positioning between the light source substrate 40 and the heat sink 50. The semicircular protrusion 53 engages with the notch 45 of the light source substrate 40, and the LED array 42 is positioned at the height of the semicircular protrusion 53.

[0020] Fixing surfaces 511, 512, 513, and 514 are each formed flat in the vertical direction and are divided into upper fixing surface 511, lower fixing surface 512, left fixing surface 513, and right fixing surface 514. Upper fixing surface 511 and lower fixing surface 512 are portions for fixing lamp unit 100 to a vehicle. Left fixing surface 513 and right fixing surface 514 are portions for fixing lens holder 20 and reflector 30.

[0021] The left fixing surface 513 and the right fixing surface 514 are configured approximately symmetrically. A lens fastening hole 54 for fastening the lens holder 20 is formed on each of the left fixing surface 513 and the right fixing surface 514. A columnar protrusion 55 is formed inside the lens fastening hole 54 to position the lens holder 20 and the reflector 30 on the one hand and the heat sink 50 on the other hand (see also FIG. 2). An engagement hole 35 of the reflector 30, which will be described later, engages with the columnar protrusion 55, and the reflector 30 is disposed in an overhead suspended position. A second fastening hole 56 for fastening the reflector 30 is formed near the height of the semicircular protrusion 53 on the other hand.

[0022] 1-3. Structure of reflector 30 2, the reflector 30 includes the abutment portions 311 and 312, the first reflecting portion 321, and the second reflecting portion 322, which are integrally formed with the elements on the back side of the reflector 30, which will be described later. In this embodiment, the light from the LED array 42 is configured to be directly incident on the lens 10, but the light leaking in the vertical direction is reflected by the first reflecting portion 321 and the second reflecting portion 322 and is configured to be incident on the lens 10 so as to compensate for the low beam and ADB light distribution described above. Since the LEDs on the LED array 42 are aligned elongated in the left-right direction, the reflector 30 is also configured to have a shape whose longitudinal direction is in the left-right direction to match this configuration.

[0023] 4 is a rear view of the reflector 30 according to the first embodiment. On the back side of the reflector 30, light extraction openings 331 and 332 are formed in two upper and lower rows between the left contact portion 311 and the right contact portion 312. In order to position the LED array 42 so that the LEDs for low beam and ADB light distribution are arranged at the heights of the light extraction openings 331 and 332, respectively, the reflector 30 is formed with a positioning portion 34 for positioning the light source substrate 40 and the reflector 30.

[0024] The positioning portions 34 have a shape that protrudes rearward (toward the heat sink 50), and their tops are formed flat so as to be in surface contact with the light source substrate 40. The positioning portions 34 are formed outside and around the lighting control region 43 (shown by dashed lines in FIG. 4 ) of the light source substrate 40 so as to avoid the lighting control region 43. In this embodiment, the positioning portions 34 are formed at the four corners close to the lighting control region 43. The positioning portions 34 position the reflector 30 relative to the light source substrate 40 (particularly the LED array 42).

[0025] The left contact portion 311 and the right contact portion 312 are formed flatly in the vertical direction and are formed to straddle the lighting control area 43. The left contact portion 311 contacts a left fixing surface 513 of the heat sink 50, and the right contact portion 312 contacts a right fixing surface 514 of the heat sink 50. The left contact portion 311 and the right contact portion 312 are configured approximately symmetrically. The left contact portion 311 and the right contact portion 312 each have an engagement hole 35 formed therein for engaging with a columnar protrusion 55 of the heat sink 50 to position the reflector 30 and the heat sink 50. In addition, a first fastening hole 36 is formed in the heat sink 50 at a position corresponding to the second fastening hole 56 formed at the height of the semicircular protrusion 53 related to the positioning of the light source. A horizontal axis connecting the left and right first fastening holes 36 is referred to as a "fastening axis 37." The fastening shaft 37 is formed with a "rotation suppressing portion 38."

[0026] The rotation suppressing portion 38 has a shape that protrudes rearward (toward the heat sink 50), and is formed so that some part of its shape is on the fastening shaft 37 and outside the positioning portion 34. In this embodiment, the rotation suppressing portion 38 has a rectangular shape with long sides perpendicular to the fastening shaft 37, and part of its surface shape is on the fastening shaft 37 and is formed on the outer edges (outermost parts) of the left contact portion 311 and the right contact portion 312.

[0027] 1-4. Assembly The assembly of the three elements of the reflector 30, light source substrate 40, and heat sink 50 configured as described above will now be described. FIG. 5 is a perspective view illustrating the assembly of the three elements of the reflector 30, light source substrate 40, and heat sink 50 in the first embodiment. First, the light source substrate 40 is positioned and placed relative to the heat sink 50 by the notches 45 and semicircular protrusions 53. Next, in this state, the reflector 30 is positioned relative to the heat sink 50 (the left fixing surface 513 and the right fixing surface 514) by the engagement holes 35 and columnar protrusions 55 and placed in front of the light source substrate 40. At this time, the reflector 30 is positioned relative to the light source substrate 40 by the positioning portions 34 formed on the reflector 30. Next, screws 70 are inserted from the reflector 30 side through the first fastening holes 36 and into the second fastening holes 56 of the heat sink 50. screw When the reflector 30 is fitted to the heat sink 50, both ends of the reflector 30 in the longitudinal direction are fixed to the heat sink 50. As a result, the light source substrate 40 is configured such that the LED array 42 is positioned within the light extraction opening 33. 1,332 The reflector 30 is sandwiched between the reflector 30 and the heat sink 50 in a state where the reflector 30 is disposed very close to the heat sink 50, and is fastened to the heat sink 50 together with the reflector 30.

[0028] The heat sink 50 (particularly the left fixing surface 513 and the right fixing surface 514) to which the light source substrate 40 and the reflector 30 are fixed is the "fixing portion" in the claims. The first fastening holes 36 formed on both longitudinal sides of the reflector 30 (the left contact portion 311 and the right contact portion 312) are the "fastening portion" in the claims.

[0029] Here, we will explain how to assemble the three elements of the reflector 30, the light source substrate 40, and the heat sink 50 when the "rotation suppression portion 38" is not formed on the reflector 30. Fig. 6 is a schematic end view for explaining how the three elements are assembled when the rotation suppression portion 38 is not formed. Fig. 6 is an end view seen from the same perspective as Fig. 7, which will be described later.

[0030] The process of assembling the three elements of the reflector 30, the light source substrate 40, and the heat sink 50 is as described in Fig. 5. Fig. 6 shows how the reflector 30 is fixed to the heat sink 50. When fixing both longitudinal sides of the reflector 30 to the heat sink 50, if the left side (1) is fixed first, the left side of the reflector 30 sinks, the reflector 30 rotates in the longitudinal direction, and the reflector 30 tilts with the right contact portion 312 protruding forward from the left contact portion 311 of the reflector 30. If the right side (2) is fixed in this state, there is a risk that the right contact portion 312 will be fixed in a position protruding forward from the correct fixing position, which could cause the reflector 30 to tilt or rattle. Furthermore, if the reflector 30 is attached to the light source board 40 in an incorrect positional relationship in the front-to-back direction of the lamp, this may affect the light distribution design, and there is also a concern that the reflector 30 may come into contact with the LED array 42.

[0031] To address this problem, in this embodiment, a "rotation suppression portion 38" is formed in the reflector 30. Fig. 7 is a cross-sectional view illustrating the assembly of three elements, i.e., the reflector 30, the light source substrate 40, and the heat sink 50, in the first embodiment, as viewed from line VII-VII in Fig. 1. Fig. 8 is an enlarged cross-sectional view of the main part of Fig. 7, enlarging the vicinity of the left-side rotation suppression portion 38.

[0032] Figure 7 also shows how the reflector 30 is fixed to the heat sink 50. As in Figure 6, when the left side (1) is fixed first, the rotation suppression portion 38 is formed as shown in Figure 8, and therefore the rotation suppression portion 38 prevents the left side of the reflector 30 from sinking, thereby suppressing rotation of the reflector 30. In this state, when the right side (2) is subsequently screwed in, even if some rotation occurs in the reflector 30, the amount is small and is corrected by tightening both sides, and the left contact portion 311 can be kept in the correct fixed position.

[0033] As described above, the lighting unit 100 of this embodiment includes the light source substrate 40, the reflector 30, and the heat sink 50 that serves as a fixing portion for these. In this configuration, the light source substrate 40 is sandwiched between the reflector 30 and the heat sink 50, the reflector 30 is positioned relative to the light source substrate 40, both longitudinal sides of the reflector 30 are fixed (fastened), and the light source substrate 40 is fastened together with the reflector 30. In this configuration, rotation of the reflector 30 can be suppressed when assembling these three elements. As a result, tilting or rattle of the reflector 30 can be prevented. Furthermore, since it is possible to avoid assembling the reflector 30 in an incorrect position, concerns about a decrease in light distribution accuracy and contact with the light source can also be avoided.

[0034] Furthermore, since the rotation suppressing portion 38 of this embodiment is formed on the fastening shaft 37 of the reflector 30 (including part of the fastening shaft 37), it is possible to suppress rotation of the reflector 30 in the up-and-down direction of the lamp. Furthermore, since the rotation suppressing portion 38 of this embodiment is formed on the outermost part of the reflector 30, the amount of rotation of the reflector 30 in the front-to-back direction is minimized. Furthermore, since the rotation suppressing portion 38 of this embodiment is formed not only on the left contact portion 311 but also on the right contact portion 312, the same effect can be obtained even when the right (2) side is fixed first and then the left (1) side is fixed.

[0035] 2. Second embodiment 9 is a rear view of the reflector 30 according to the second embodiment. In the second embodiment, the rotation suppressing portion 38 has a circular shape whose center coincides with the fastening shaft 37, and is formed only on the right contact portion 312. By locating the center of the rotation suppressing portion 38 on the fastening shaft 37 in this way, it is possible to further suppress rotation of the reflector 30 in the up-down direction of the lamp. Furthermore, if the side to be fastened first is determined in the manufacturing process of the lamp unit 100, it is sufficient that at least one rotation suppressing portion 38 is formed on that side.

[0036] 3. Third embodiment FIG. 10 is a rear view of a reflector 30 according to a third embodiment. In the third embodiment, the rotation suppressing portions 38 are trapezoidally formed at positions not coaxial with the fastening shaft 37, two on each of the right contact portion 312 and the left contact portion 311 (four in total). As described above, the surface shape of the rotation suppressing portions 38 is not limited as long as they have a protruding shape on the heat sink 50 side, which is the fixed portion. The number of rotation suppressing portions formed is also not limited. Furthermore, the rotation suppressing portions 38 of this embodiment are formed at positions that are not the outermost of the reflector 30. As described above, the position of the rotation suppressing portions 38 is not limited as long as they are outside the positioning portions 34 between the light source substrate 40 and the reflector 30. However, forming the rotation suppressing portions 38 outside the first fastening holes 36 ("fastening portions") is preferable because it minimizes the amount of rotation of the reflector 30 in the forward / backward direction compared to a configuration in which the rotation suppressing portions 38 are inside the first fastening holes 36.

[0037] 4. Fourth Embodiment 11 is a front view of a heat sink 50 according to the fourth embodiment. In the fourth embodiment, the heat sink 50 is formed with corresponding rotation suppression portions 58 that correspond in position to the rotation suppression portions 38 of the reflector 30. The corresponding suppression portions 58 are formed on the left fixing surface 513 and the right fixing surface 514 of the heat sink 50, and have a protruding shape in the forward direction (toward the lens 10).

[0038] Fig. 12 is an enlarged cross-sectional view of a main part of the assembly in the fourth embodiment. Like Fig. 7, Fig. 12 also shows the assembly of the three elements of the reflector 30, the light source substrate 40, and the heat sink 50, and like Fig. 8, is an enlarged cross-sectional view of the vicinity of the left rotation suppression part 38.

[0039] In the fourth embodiment, when the left side (1) is first fixed, a corresponding suppression portion 58 that corresponds in position to the rotation suppression portion 38 is formed on the heat sink 50, so that the rotation suppression portion 38 is engaged with the corresponding suppression portion 58, thereby suppressing rotation of the reflector 30.

[0040] Since the positional accuracy of the reflector 30 is achieved by the positioning portion 34 with respect to the light source substrate 40, the manufacturing accuracy standards for the reflector 30 can be relaxed by proactively providing a clearance between the rotation suppressing portion 38 and the heat sink 50. The rotation suppressing portion 38 suppresses rotation of the reflector 30, which inevitably occurs when a clearance is provided. Here, in the fourth embodiment, rotation is suppressed by the rotation suppressing portion 38 on the reflector 30 side and the corresponding suppressing portion 58 on the heat sink 50 side. By providing the reflector 30 and the heat sink 50 with protruding shapes, the manufacturing accuracy standards for the reflector 30 can be further relaxed.

[0041] The above describes preferred embodiments of the present invention, but the above embodiments are examples of the present invention, and these can be combined based on the knowledge of those skilled in the art, and such forms are also included in the scope of the present invention. [Explanation of symbols]

[0042] 100 lighting units 10 Lenses 20 Lens holder 30 Reflector 311 Left side contact part 312 Right side contact part 321 First reflection section 322 Second reflection section 331, 332 Light extraction opening 34 Positioning part 35 Engagement hole 36 First fastening hole (fastening part) 37 Fastening shaft 38 Rotation suppression section 40 Light source board 42 LED array (light source) 43 Lighting control area 45 Notch 50 Heat sink (fixed part) 511 Upper fixed surface 512 Lower fixed surface 513 Left side fixed surface 514 Right side fixed surface 52 Substrate storage section 53 Semicircular protrusion 54 Lens fastening part 55 Columnar process 56 Second fastening hole 58 Response Suppression Department 60 Cooling fan 70 screws

Claims

1. a light source substrate on which a light source is mounted, a reflector that reflects light from the light source, and a fixing portion to which the light source substrate and the reflector are fixed, the light source substrate is sandwiched between the reflector and the fixing portion, the reflector is positioned relative to the light source board by a positioning portion for the light source board, and is fixed to the fixing portion by a screw at fastening portions on both sides of the longitudinal direction of the reflector; the reflector has a protruding rotation suppressing portion in a direction toward the fixed portion, The rotation suppression portion is formed outside the positioning portion, and is in a non-contact state with the fixing portion when the reflector is not fixed to the fixing portion, and when fixed with the screw, it prevents the fixed side of the reflector from sinking, thereby suppressing the rotation of the reflector.

2. The lamp unit according to claim 1, wherein the rotation suppressing portion is formed coaxially with a fastening axis that connects the fastening portions on both sides in the longitudinal direction.

3. The lamp unit according to claim 2, wherein the rotation restricting portion is formed in a surface shape that includes the fastening shaft as a part thereof.

4. 4. The lamp unit according to claim 1, wherein at least one of the rotation restricting portions is formed on one of both longitudinal sides that is fastened first in a manufacturing process.

5. 5. The lamp unit according to claim 1, wherein the rotation suppressing portion is formed on the outermost side of the reflector.

Images