Resin reflectors for vehicle lighting fixtures

Abstract

To provide a reflector that has a reflection part with a plurality of front reflection regions enumerated, and in which deformation is hard to occur.SOLUTION: A resin reflector 1 for a vehicle lamp has: a reflection part 2 having a plurality of front reflection regions 3 to 6 enumerated; an upper wall part 7 integrally molded at an upper end part 2a of the reflection part 2; and a lower wall part 8 integrally molded at a lower end part of the reflection part 2. The resin reflector 1 for a vehicle lamp has continuous reinforcing ribs 15 to 18 integrally formed so as to straddle the outer peripheral surfaces of the lower wall part 8, the reflection part 2 and the upper wall part 7.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] A technology relating to a reflector having a reflective portion with a plurality of arranged forward reflective regions. [Background technology]

[0002] 1 and 2 of Patent Document 1 disclose a headlamp that includes a resin reflector having a reflective surface that is rectangular in front view and one filament-type headlamp bulb (light bulb) disposed in the center of the resin reflector.

[0003] The resin reflector of Patent Document 1 has an upper wall portion protruding forward from the upper end of a reflecting portion having a parabolic reflecting surface as shown in Figure 2, a lower wall portion protruding forward from the lower end of the reflecting portion, and a reinforcing rib 3C formed on the outer peripheral surface of the back side of the reflecting surface having a parabolic surface shape. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 11-185503 Summary of the Invention [Problem to be solved by the invention]

[0005] Many of the headlamps used in automobiles in recent years have adopted LEDs as the light source, and some LED headlamps reflect the light emitted from multiple LED light sources by a reflector with reflective surfaces arranged on the left and right sides of each LED light source to diffuse and sufficiently illuminate the light, which has low diffusion and illuminance. This type of reflector is horizontally long overall, and the upper and lower wall portions of the reflective portion are also horizontally long.

[0006] When the upper and lower wall portions of a horizontally elongated resin reflector are removed from the mold after molding and cooled to harden, they may cool and harden earlier than the reflective portion due to differences in wall thickness. The reflective portion, which hardens later than the upper and lower wall portions, may experience thermal shrinkage, and the thermal shrinkage in the reflective portion may cause deformation such that the front ends of the upper and lower wall portions collapse inward. This deformation of the upper and lower wall portions of the reflector collapsing inward causes deformation of part of the reflective surface, which is problematic in that it adversely affects the shape of the cut-off line of the displayed headlamp light distribution pattern.

[0007] In view of the above problems, the present application provides a resin reflector for vehicle lighting fixtures that is less likely to undergo deformation such that the upper and lower wall portions of the reflector collapse inward when cooled and solidified, and that is less likely to adversely affect the shape of the cutoff line of the headlamp light distribution pattern. [Means for solving the problem]

[0008] In a resin reflector for a vehicle lamp having a reflective section with a plurality of arranged forward reflective areas, an upper wall section integrally molded at the upper end of the reflective section, and a lower wall section integrally molded at the lower end of the reflective section, a continuous reinforcing rib is provided that is integrally formed so as to straddle the outer peripheral surfaces of the lower wall section, the reflective section, and the upper wall section.

[0009] (Effect) By connecting the reinforcing ribs on the lower wall portion and the outer wall of the lower wall portion of the reflector with the reinforcing rib on the outer surface of the reflective portion to form a continuous reinforcing rib, even if thermal shrinkage occurs in the reflective portion of the reflector when it is ejected from the mold, the upper wall portion and the lower wall portion are less likely to bend inward.

[0010] Furthermore, in a resin reflector for a vehicle lamp, it is desirable that the upper wall portion has a rear wall portion that protrudes rearward from the upper end of the reflective portion, and that the continuous reinforcing rib is formed continuously and integrally so as to span the outer peripheral surfaces of the lower wall portion, the reflective portion, and the rear wall portion of the upper end.

[0011] (Effect) By providing a rear wall portion on the upper wall portion and forming a continuous reinforcing rib that is continuous with the lower wall portion and the reflective portion integrally and continuously to the outer periphery of the rear wall portion, the upper wall portion and the lower wall portion become even less likely to bend even if thermal shrinkage occurs in the reflective portion of the reflector.

[0012] In the resin reflector for a vehicle lamp, it is preferable that the thickness of at least one of the upper wall portion and the lower wall portion is thinner than the thickness of the reflecting portion.

[0013] (Effect) Inward deformation of the upper and lower wall portions due to thermal shrinkage deformation occurring in the reflective portion of the reflector is most likely to occur when the upper and lower wall portions are formed thinner than the reflective portion. Therefore, by connecting the reinforcing ribs on the upper and lower wall portions, at least one of which is formed thinner than the reflective portion, with a reinforcing rib on the outer peripheral surface of the reflective portion to form a continuous reinforcing rib, the upper and lower wall portions are less likely to bend inward even if thermal shrinkage occurs in the reflective portion of the reflector.

[0014] In the resin reflector for a vehicle lamp, it is preferable that the continuous reinforcing rib is formed on the back surface of each of the plurality of reflective areas of the reflective portion. (Operation) By forming the continuous reinforcing rib for each of the plurality of reflecting regions of the reflecting part, even if thermal shrinkage occurs in the reflecting part of the reflector, the upper wall part and the lower wall part become even less likely to bend.

[0015] In the resin reflector for a vehicle lamp, it is preferable that a plurality of the continuous reinforcing ribs are formed on the rear surface of each of the plurality of reflective areas of the reflective portion.

[0016] (Operation) By forming a plurality of continuous reinforcing ribs for each of a plurality of reflecting regions of the reflecting part, even if thermal shrinkage occurs in the reflecting part of the reflector, the upper wall part and the lower wall part become even less likely to bend. [Effects of the Invention]

[0017] With a resin reflector for vehicle lighting fixtures, the upper and lower wall portions of the reflector are less likely to be deformed inward when cooled and solidified after being ejected from a mold, which reduces the likelihood of adverse effects on the cutoff line shape of the headlamp light distribution pattern.

[0018] Furthermore, when the reflector is cooled and solidified upon injection from the mold, the inward deformation that occurs in the upper and lower wall portions of the reflector is more likely to occur because the thinner upper and lower wall portions, which cool and solidify first, are affected by the thermal contraction deformation of the thicker portion, which cools and solidifies later. Therefore, according to the resin reflector for vehicle lighting fixtures of the present application, even if thermal contraction occurs in the thick reflective portion of the reflector, the reflective portion is connected to the upper and lower wall portions by a single continuous reinforcing rib that is formed continuously from the reflective portion to the upper and lower wall portions, making it less likely that the upper and lower wall portions will bend inward.

[0019] Furthermore, in the resin reflector for vehicle lighting fixtures, continuous reinforcing ribs provided in each of the multiple reflective areas of the reflective portion make the upper and lower wall portions even less likely to bend even if thermal shrinkage occurs in the reflective portion of the reflector.

[0020] Furthermore, in the resin reflector for vehicle lighting fixtures, multiple continuous reinforcing ribs are provided for each of the multiple reflective areas of the reflective portion, making the upper and lower wall portions even less likely to bend even if thermal shrinkage occurs in the reflective portion of the reflector. [Brief explanation of the drawings]

[0021] [Figure 1] 1 is a front view of a resin reflector for a vehicle lamp according to a first embodiment of the present invention; [Figure 2] 1 is a reference perspective view of a resin reflector for a vehicle lamp according to a first embodiment of the present invention, as viewed from diagonally front right and diagonally above right. [Figure 3] 1 is a reference perspective view of a resin reflector for a vehicle lamp according to a first embodiment of the present invention, viewed from diagonally rear right and diagonally below right. [Figure 4]2 is a reference cross-sectional view of a vehicle lamp including a resin reflector for a vehicle lamp according to a first embodiment of the present invention, taken along line II in FIG. 1; [Figure 5] 1A is a cross-sectional view showing a resin reflector for a vehicle lamp according to a second embodiment of the present invention, and FIG. 1B is a cross-sectional view showing a resin reflector for a vehicle lamp according to a third embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0022] A first embodiment of a resin reflector for a vehicle lamp according to the present invention will be described below with reference to Figures 1 to 4. In each figure, the directions relative to the vehicle are described as (upper: lower: left: right: front: rear = Up: Lo: Le: Ri: Fr: Re).

[0023] 1 and 2 show, as an example, a resin reflector 1 for a vehicle lamp of the present invention. The resin reflector 1 for a vehicle lamp is a reflector for a left headlamp of a vehicle, and has a reflective section 2 having a plurality of reflective areas 3 to 6 aligned and integrated on the left and right, an upper wall section 7 formed integrally with an upper end section 2a of the reflective section 2 (see FIG. 4), and a lower wall section 8 formed integrally with a lower end section 2b of the reflective section 2 (see FIG. 4), and is formed in a horizontally elongated shape extending left and right.

[0024] As shown in Figures 1 and 2, the reflective areas 3 to 6 are formed as four reflective areas separated by partition walls 9 to 11, respectively. The four reflective areas 3 to 6 are just an example, and the number of reflective areas arranged on the left and right is not limited to four, as long as there are multiple reflective areas. The reflective areas 3 to 6 have mirror-like reflective surfaces 3a to 6a that reflect light from the light source forward. The upper surface of the lower wall 8 is provided with knurling 8a to 8d, which are made up of numerous groove-like uneven portions extending forward and backward, and are provided at positions corresponding to the front ends of the reflective surfaces 3a to 6a, respectively. The partition walls 9 to 11 are also provided with knurling 9a to 11a, which are made up of numerous groove-like uneven portions.

[0025] 2, the upper wall 7 is provided with light source mounting holes 3b to 6b, which are upper and lower through-holes for fixing light source substrates (only light source substrate 12 of reflective area 5 is shown in FIG. 4. The other light source substrates have the same configuration but are not shown) for each of the reflective areas 3 to 6. As shown in FIG. 4, the light source substrate 12 is made up of a light source 13 such as an LED light-emitting element and a substrate 14, and is fixed to the upper surface 7a (outer peripheral surface) of the upper wall 7 with the light source 13 facing downward and inserted into the light source mounting hole 5b.

[0026] 3, the upper wall 7 of the resin reflector 1 for vehicle lighting is provided with rear wall portions 7b extending rearward from the upper end portions 2a of the reflective areas 3 to 6 that form the reflective portion 2. Furthermore, continuous reinforcing ribs 15 to 18 are provided on the back surfaces (outer peripheral surfaces) of the reflective areas 3 to 6 of the reflective portion, one at the center on the left and right of each of the reflective areas 3 to 6. The continuous reinforcing ribs 15 to 18 are integrally formed so as to straddle the lower surface (outer peripheral surface) of the lower wall 8, the back surfaces (outer peripheral surfaces) of the reflective areas 3 to 6, and the lower surface (outer peripheral surface) of the upper wall, respectively.

[0027] As shown in Fig. 3, the vehicle lamp resin reflector 1 is provided with a bracket 19 for upper and lower aiming screws, a bracket 20 for left and right aiming screws, and an aiming fulcrum bracket 21, which are formed to extend rearward. As shown in Fig. 4, the vehicle lamp resin reflector 1 is fixed to the lamp body 22 by upper and lower aiming screws 24 and left and right aiming screws (not shown) which are screwed into aiming nuts (not shown) provided on the bracket 19 for upper and lower aiming screws and the bracket 20 for left and right aiming screws, respectively, and by an aiming fulcrum member 25 which is attached to a spherical hole-shaped aiming fulcrum receiving portion (not shown) provided on the aiming fulcrum bracket 21 so as to be able to swing. The vehicle lamp resin reflector 1 is provided in the lamp chamber S inside the lamp body 22 and the front cover 23, constitutes a part of the left vehicle headlamp which is a vehicle lamp, and is tiltable up, down, left, and right by the upper and lower aiming screws 24 and left and right aiming screws (not shown).

[0028] 4, the thickness t1 of the reflective area 5 (the same applies to the reflective areas 3, 4, and 6) that form the reflective portion of the resin reflector 1 for vehicle lighting is preferably formed to be thicker than the thickness t2 of each of the upper wall portion 7 and the lower wall portion 8 (t1>t2), but may also be the same thickness (t1=t2). Also, the thicknesses of the upper wall portion 7 and the lower wall portion 8 may be different dimensions.

[0029] 1 to 4 is injected from a mold, the upper wall 7 and the lower wall 8 cool and solidify first, and the reflective portion 2 (reflective areas 3 to 6), which is thicker than the upper wall 7 and the lower wall 8, cools and solidifies later. In the reflective reflector 1 for a vehicular lamp of this embodiment shown in Figures 3 and 4, continuous reinforcing ribs 15 to 18 are provided on the back surfaces of the reflective areas 3 to 6, respectively. However, if the continuous reinforcing ribs 15 to 18 were not provided, the left and right central portions 7d of the upper wall 7 of the reflective reflector 1 for a vehicular lamp shown in Figure 1 would bend downwardly convexly due to thermal contraction deformation that later occurs in the reflective areas 3 to 6, and the left and right central portions 8f of the lower wall 8 would also bend upwardly convexly, resulting in problems such as deformation of the centers of both the upper wall 7 and the lower wall 8 so that they collapse inward.

[0030] According to the resin reflector 1 for a vehicle lamp, continuous reinforcing ribs 15-18 protruding rearward are provided on the rear surfaces of the reflective areas 3-6, and the continuous reinforcing ribs 15-18 have the same configuration as the continuous reinforcing rib 17 shown in Fig. 4. The continuous reinforcing rib 17 is a single, continuous, integral rib consisting of a first rib 17a integrated with the lower surface 8e of the lower wall 8, a second rib 17b integrated with the rear surface of the reflective area 5, and a third rib 17c integrated with the lower surface 7c of the rear wall 7b of the upper wall 7. This makes it difficult for the centers of the upper wall 7 and the lower wall 8 to deform inward. The continuous reinforcing ribs 15-18 prevent deformation of the upper wall 7, thereby preventing deformation of the light source mounting holes 3b-6b, and therefore preventing misalignment of the mounting position of the light source 13 on the mounted light source board 12.

[0031] Furthermore, deformation of the upper wall portion 7 and the lower wall portion 8 of the vehicle lamp resin reflector 1 causes deformation of the cutoff line forming surfaces of the reflective areas 3 to 6, thereby deforming the light distribution pattern into a shape that deviates from the originally desired shape, so that the continuous reinforcing ribs 15 to 18 prevent deformation of the upper wall portion 7 and the lower wall portion 8, and therefore, according to the vehicle lamp resin reflector 1 of this embodiment, deformation of the light distribution pattern that deviates from the predetermined shape is less likely to occur. As shown in Fig. 4, light L1 emitted from the light source 13 is reflected forward of the front lens 23 by the reflective surface 5a of the reflective area 5 and the knurling 8c, and the reflected light L1 by the reflective surface 5a displays a light distribution pattern of the predetermined shape without deformation.

[0032] 3, the continuous reinforcing ribs 15-18 provided for each of the reflective areas 3-6 of the reflective section 2 do not necessarily have to be provided for each reflective area, but from the viewpoint of realizing stronger prevention of deformation of the upper wall section 7 and the lower wall section 8, it is desirable to provide one for each of the reflective areas 3-6 as much as possible. Furthermore, the continuous reinforcing ribs 15-18 are not limited to being provided in one location for each reflective area as in this embodiment, and it is more desirable to provide multiple continuous reinforcing ribs for each reflective area.

[0033] Next, a second embodiment of the resin reflector for a vehicle lamp of the present invention will be described with reference to Fig. 5(a). The resin reflector for a vehicle lamp 31 in the second embodiment has a structure in common with the resin reflector for a vehicle lamp 1, except that the shape of the continuous reinforcing rib 35 is different from the continuous reinforcing ribs 15 to 18 in the first embodiment.

[0034] Specifically, as shown in FIGS. 4 and 5(a), the continuous reinforcing rib 17 in the first embodiment has the third rib 17c only on the underside 7c of the rear wall portion 7b of the upper wall portion 7. However, the continuous reinforcing rib 35 in the second embodiment differs from the continuous reinforcing rib 17 in that the third rib 35c is integrally formed not only on the underside 7c (outer peripheral surface) of the rear wall portion 7b but also on the rear side 7e (outer peripheral surface) and the upper side 7f (outer peripheral surface). The third rib 35c is continuously and integrally formed with the first rib 35a integrated with the lower wall portion 8 and the second rib 35b provided on the back surface of the reflective area 5. Since the third reinforcing rib 35c is also formed on the rear side 7e and the upper side 7f of the rear wall portion 7b, the continuous reinforcing rib 35 is stronger than the continuous reinforcing ribs 15 to 18 in the first embodiment during thermal contraction deformation of the reflective portion 2, and prevents the upper wall portion 7 and the lower wall portion 8 from collapsing inward.

[0035] Next, a third embodiment of the vehicle lamp resin reflector of the present invention will be described with reference to Fig. 5(b). The vehicle lamp resin reflector 41 of the third embodiment has a structure in common with the vehicle lamp resin reflector 1 of the first embodiment, except that the upper wall 7' of the reflective portion 2' does not have a rear wall 7b, unlike the upper wall 7 of the first embodiment, and the shape of the continuous reinforcing rib 45 is different from the continuous reinforcing ribs 15 to 18.

[0036] 5 is a rib formed by continuously and integrally forming a first rib 45a integrated with the lower surface 8e' of the lower wall portion 8', a second rib 45b integrated with the back surface of the reflective area 5', and a third rib 45c integrated with the upper surface 7f' (outer peripheral surface) of the upper wall portion 7' ​​that does not have a rear wall portion. According to the continuous reinforcing rib 45 of this embodiment, even in a resin reflector for a vehicle lamp that does not have a rear wall portion on the upper wall portion, by providing the third rib 45c on the upper surface 7f' of the upper wall portion 7', it is possible to prevent deformation in which both the upper wall portion 7' ​​and the lower wall portion 8 collapse inward. [Explanation of symbols]

[0037] 1 Resin reflectors for vehicle lighting fixtures 2 Reflector 2a Upper end 2b Lower end 3~6 Reflection Zone 3a~6a Reflecting surfaces 7. Upper wall 7a above 7b Rear wall portion 7c below 7e after 7f above 8. Lower wall portion 8e below 9~11 Shiqiebi 15~18 Continuous reinforcement rib t1 The thickness of the reflective part t2 The thickness of the upper wall and lower wall

Claims

1. A reflector having a plurality of front reflective areas arranged in a row, and a reflector integrally formed on the upper end of the reflector. and a lower wall portion integrally formed with the lower end of the reflecting portion. In the case of a resin reflector, The lower wall portion, the reflecting portion, and the upper wall portion are integrally formed so as to straddle the outer peripheral surfaces of the lower wall portion, the reflecting portion, and the upper wall portion. having a continuous reinforcing rib; the upper wall portion includes a rear wall portion that protrudes rearward from an upper end of the reflecting portion, A resin reflector for a vehicle lamp, characterized in that the continuous reinforcing rib is formed continuously and integrally so as to straddle the outer peripheral surfaces of the lower wall portion, the reflecting portion, and the rear wall portion of the upper end portion.

2. The thickness of at least one of the upper wall portion and the lower wall portion is thinner than the thickness of the reflecting portion.

2. The resin reflector for a vehicle lamp according to claim 1, wherein the resin reflector is formed of a resin material.

3. The continuous reinforcing rib is formed on the back surface of each of the plurality of reflective areas of the reflective part.

2. The resin reflector for a vehicle lamp according to claim 1,

4. The continuous reinforcing rib is formed on the back surface of each of the plurality of reflective areas of the reflective part.

2. The resin reflector for a vehicle lamp according to claim 1,

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