Headlight module

Abstract

A headlight module comprising: an incidence part (110) onto which light from a light source (1) is incident and which has a plurality of joint surfaces (111)-(115) located along one direction in a plane perpendicular to the optical axis of the light source; a collective light guide part (120) that has a plurality of exit surfaces (121a)-(125a), which correspond to the plurality of joint surfaces (111)-(115), respectively, of the incidence part (110) and which are located along another direction perpendicular to the one direction in the plane perpendicular to the optical axis of the light source (1), and that guides light from each of the corresponding joint surfaces (111)-(115) to the exit surfaces (121a)-(125a) corresponding thereto; and a light distribution forming part (200) that has at least one projection surface (231a)-(233a) located along the other direction, reflects the light from the plurality of exit surfaces (121a)-(125a) toward one end side in the one direction, and guides the reflected light to the projection surfaces (231a)-(233a), wherein the light distribution forming part (200) combines and guides the light from at least two adjacent exit surfaces (121a)-(125a), among the plurality of exit surfaces (121a)-(125a), to one of the projection surfaces (231a)-(233a).

Description

[Technical Field]

[0001] The present disclosure relates to a headlamp module used in, for example, a headlamp device that illuminates the area ahead of a vehicle body. [Background technology]

[0002] BACKGROUND ART Headlight devices that illuminate the area ahead of a vehicle body, so-called headlight devices, particularly low-beam headlights and high-beam headlights, are desired to be thin and have improved light utilization efficiency. Patent Document 1 proposes a headlamp module that has a simplified structure and is compact without reducing light utilization efficiency.

[0003] The headlamp module proposed in Patent Document 1 includes a light source distribution element for a headlamp device, a first cutoff line forming portion, and a second cutoff line forming portion. The light source distribution element for a headlamp device includes a first light guiding section located between the first bonding surface of the incident section and the first exit section, and guiding light from the first bonding surface of the incident section to the first exit section; and a second light guiding section located between the second bonding surface of the incident section and the second exit section, and having a first reflecting surface formed on one of the opposing side surfaces in the other direction and a second reflecting surface formed on the other of the opposing side surfaces in the other direction, and reflecting the light from the second bonding surface of the incident section by the first reflecting surface and the second reflecting surface to guide it to the second exit section.

[0004] The first cutoff line forming portion is formed integrally with the first exit surface of the first exit portion, and emits light in which a cutoff line is formed with respect to light emitted from the first exit surface. The second cutoff line forming portion is formed integrally with the second exit surface of the second exit portion, and emits light in which a cutoff line is formed with respect to light emitted from the second exit surface. The headlamp module proposed in Patent Document 1 has a simple structure and can be made thinner and more compact in height in the vertical direction without reducing light utilization efficiency. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Patent No. 7,031,087 Summary of the Invention [Problem to be solved by the invention]

[0006] There is a demand for a headlight module with an even lower height as a headlight device for a vehicle, and the present disclosure has been made in response to such a demand, and aims to obtain a headlight module that is even thinner and smaller without reducing the light utilization efficiency by simplifying the structure. [Means for solving the problem]

[0007] The headlight module according to the present disclosure comprises an entrance section into which light from a light source is incident and which has a plurality of bonding surfaces located along one direction in a plane orthogonal to the optical axis of the light source; a collective light-guiding section which has a plurality of exit surfaces corresponding to the plurality of bonding surfaces of the entrance section and located along another direction orthogonal to the one direction in the plane orthogonal to the optical axis of the light source, each of which guides light from the corresponding bonding surface to the corresponding exit surface; and a light distribution forming section which has at least one projection surface located along the other direction and reflects light from the plurality of exit surfaces to one end side in one direction and guides it to the projection surface, and the light distribution forming section combines and guides light from at least two or more adjacent exit surfaces of the plurality of exit surfaces to one of the projection surfaces. [Effects of the Invention]

[0008] According to the present disclosure, the structure can be simplified and the device can be made thinner and smaller without reducing the light utilization efficiency. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a perspective view showing a headlight module according to a first embodiment, viewed from above on the right side. [Figure 2] 1 is a perspective view showing a headlight module according to a first embodiment, as viewed from the left side. [Figure 3] 1 is a perspective view showing a headlight module according to a first embodiment, viewed from below on the right side. [Figure 4] 1 is a front view showing a headlight module according to a first embodiment. [Figure 5] 1 is a top view showing a headlight module according to a first embodiment. [Figure 6] 2 is a bottom view showing the headlight module according to the first embodiment. FIG. [Figure 7] 1 is a side view showing a headlight module according to a first embodiment. [Figure 8] 1 is a front view showing a part of a cross section of an incident portion of a headlight module according to a first embodiment. [Figure 9] 4 is a diagram showing an illuminance distribution at a joint surface in an incident portion of the headlight module according to the first embodiment. FIG. [Figure 10] 3 is a perspective view showing a light beam in the headlight module according to the first embodiment, as viewed from above on the right side. FIG. [Figure 11] 2 is a top view showing a light beam in the headlight module according to the first embodiment. FIG. [Figure 12] 3 is a rear view showing a light beam in the headlight module according to the first embodiment. FIG. [Figure 13] 3 is a side view showing a light beam in the headlight module according to the first embodiment. FIG. [Figure 14] FIG. 10 is a perspective view showing a headlight module according to a second embodiment, as viewed from below on the right side. [Figure 15] FIG. 11 is a perspective view showing a headlight module according to a third embodiment, viewed from below on the right side. DETAILED DESCRIPTION OF THE INVENTION

[0010] Embodiment 1 A headlamp module according to a first embodiment will be described with reference to FIGS. The headlight module is used in headlight devices that illuminate the area ahead of automobiles, motorcycles, and three-wheeled vehicles known as gyros (scooters and motorized bicycles with one front wheel and two rear wheels on a single axle), and that satisfy specified light distribution patterns stipulated by road traffic regulations, etc. The headlamp device has a low beam and a high beam.

[0011] The headlamp module according to the first embodiment can be used for low beam and high beam, but is particularly suitable for use in low beam. In the following description, an example in which the present invention is applied to a low beam headlamp device for an automobile will be described. When applied to a low beam headlamp device for an automobile, the headlamp module may be one, or a plurality of headlamp modules may be arranged in parallel in the left-right direction.

[0012] Before specifically describing the headlamp module, the terms used in this disclosure will be explained. Light distribution refers to the spatial distribution of luminous intensity of a light source, i.e., the spatial distribution of light emitted from a light source. Luminous intensity indicates the degree of strength of light emitted by a light source, and is calculated by dividing the luminous flux passing through a small solid angle in a certain direction by that small solid angle.

[0013] Road traffic regulations require that the low beams of automobile headlight devices and motorcycle headlight devices have a horizontally elongated light distribution pattern that is narrow in the vertical direction, and that the upper light boundary line of the light distribution pattern, i.e., the cut-off line, be clear so as not to dazzle drivers of oncoming vehicles. The light distribution pattern refers to the shape of the light flux and the light intensity distribution resulting from the direction of light emitted from the light source 1. The light distribution pattern is also used to mean the illuminance pattern on the illuminated surface. The luminous intensity distribution is the distribution of light intensity relative to the direction of light emitted from a light source. The luminous intensity distribution is also used to mean the illuminance distribution on an illuminated surface.

[0014] The required clear cutoff line means that the upper side of the cutoff line, i.e., the outside of the light distribution pattern, is dark, and the lower side of the cutoff line, i.e., the inside of the light distribution pattern, is bright.

[0015] The cut-off line is a dividing line between light and darkness that is created when light from a headlight device is projected onto a wall or a screen, and is the dividing line at the top of the light distribution pattern. That is, the cutoff line is the boundary line between the bright and dark areas of the upper part of the light distribution pattern. It is the boundary line between the bright area of ​​the upper part of the light distribution pattern, i.e., the inside of the light distribution pattern, and the dark area, i.e., the outside of the light distribution pattern. The cutoff line is a term used when adjusting the illumination direction of a passing headlight device. A passing headlight device is also called a low beam.

[0016] Low beams are required to have maximum illuminance in the area below the cutoff line, which is called the high illuminance area. The area below the cutoff line means the upper part of the light distribution pattern, which corresponds to the part of the headlamp device that irradiates a distant object. To achieve a clear cutoff line, the cutoff line must not have large chromatic aberration or blur, etc. Blurring of the cutoff line means that the cutoff line is unclear.

[0017] In a low beam headlamp device for an automobile, the cut-off line has a stepped shape with a rising line. In a low beam motorcycle headlamp device, the cutoff line is a horizontal straight line in the left-right direction of the vehicle, and the light distribution pattern is brightest below the cutoff line, i.e., in the area inside the light distribution pattern. Furthermore, because headlight devices are disposed at the front of an automobile, design is important, and there is a demand for headlight devices that offer increased freedom in design. If a headlamp device is designed to be thin in the vertical direction of the vehicle in order to enhance design, the light utilization efficiency will be low.

[0018] The headlight module according to the first embodiment includes a light source distribution element 100 for a headlight device (hereinafter referred to as the light source distribution element 100) and a light distribution forming unit 200. The light source distribution element 100 lowers the apparent height of the light source 1, thereby reducing the vertical direction, i.e., the height, of the projection surfaces 231a to 233a of the light distribution forming unit 200 arranged in the left-right direction, and reducing the horizontal direction, i.e., the width, to improve design, and by focusing on Abbe's invariant (Abbe's sine condition or the law of conservation of etendue), the headlight module is made thinner and smaller without reducing light utilization efficiency.

[0019] That is, by making the light source distribution element 100 have five exit surfaces 121a to 125a, the length of the front-to-back sides of the exit surface of the light source distribution element 100, which serves as the apparent light source, and the length of the up-to-down sides of the projection surface of the light distribution forming unit 200 can be made shorter, and by making the projection surface of the light distribution forming unit 200 have three projection surfaces 231a to 233a, the length of the left-to-right sides of the projection surface of the light distribution forming unit 200 can be made shorter, thereby making the light distribution forming unit 200 thinner and more compact.

[0020] In order to avoid complexity in the explanation, the following description will focus on the light source distribution element 100 in which the exit surface of the light source distribution element 100, specifically the exit surface of the collective light-guiding section 120 that constitutes the light source distribution element 100, is five exit surfaces 121a to 125a, and the projection surface of the light distribution forming section 200 is three projection surfaces 231a to 233a. However, the collective light-guiding section 120 may have a plurality of exit surfaces, and the number of projection surfaces of the light distribution forming section 200 may be less than the number of exit surfaces of the collective light-guiding section 120 . In this case, the light distribution forming section 200 combines and guides light from at least two or more adjacent exit surfaces among the plurality of exit surfaces 121a to 125a of the light source distribution element 100 to one of the projection surfaces 231a to 233a.

[0021] In the following description, for ease of explanation, XYZ coordinates will be used. The left-right direction of the vehicle is the X-axis direction. The right side of the vehicle is the + direction of the X-axis, and the left side is the - direction of the X-axis. Here, "forward" refers to the direction in which the vehicle is traveling. In other words, "forward" refers to the direction in which the headlight device emits light. In the headlight module according to the first embodiment, the X-axis direction is the other direction, with one end side being the negative direction (right side) and the other end side being the positive direction (left side). Although one end side is the right side and the other end side is the left side, this is specified for convenience of explanation, and one end side may be the left side and the other end side may be the right side.

[0022] The vertical direction of the vehicle is the Y-axis direction. The upper side is the + direction of the Y-axis, and the lower side is the - direction of the Y-axis. The upper side is the direction of the sky, and the lower side is the direction of the ground (road surface, etc.). The direction of travel of the vehicle is the Z-axis direction. The direction of travel is the + direction of the Z-axis, and the opposite direction is the - direction of the Z-axis. The + direction of the Z-axis is called the front, and the - direction of the Z-axis is called the rear. In other words, the + direction of the Z-axis is the direction in which the headlights emit light. In the headlight module according to embodiment 1, the Z-axis direction is one direction, with one end side being the + direction, which is the front when used for an automobile, and the other end side being the - direction, which is the rear when used for an automobile.

[0023] The ZX plane is parallel to the road surface. The road surface is usually considered to be a horizontal plane, that is, a plane perpendicular to the direction of gravity, although the road surface may be inclined relative to the direction of travel of the vehicle due to an uphill or downhill slope, for example. Furthermore, although it is rare for a typical road surface to be inclined left or right with respect to the direction of travel of a vehicle, that is, in the width direction of the road, the road surface may be inclined left or right. Therefore, the horizontal plane, which is a plane parallel to the road surface, is not necessarily a plane perpendicular to the direction of gravity, but the following explanation will be given assuming that the horizontal plane is a plane perpendicular to the direction of gravity, and that the ZX plane is a plane perpendicular to the direction of gravity.

[0024] The headlamp module will be specifically described below. The headlamp module includes a light source distribution element 100 and a light distribution forming part 200, as shown in FIGS. The headlamp device further comprises a light source 1 in addition to the headlamp module. The light source 1 emits light to illuminate the area ahead of the vehicle. The light source 1 is disposed on the negative side of the Y axis of the light source distribution element 100, and emits light in the positive direction of the Y axis. The optical axis of the light source 1 is an axis along the Y axis direction.

[0025] The light source 1 has a rectangular emission surface that emits light to the front. The light source 1 is either a tube light source such as an incandescent lamp, a halogen lamp, or a fluorescent lamp, or a semiconductor light source such as a light emitting diode (LED, hereinafter referred to as LED) or a laser diode (LD, hereinafter referred to as LD). From the perspective of reducing the burden on the environment by reducing carbon dioxide (CO2) emissions and fuel consumption, it is preferable to use semiconductor light sources, which have higher luminous efficiency than halogen lamps, are directional, and allow for smaller and lighter optical systems. The headlamp device of the present disclosure uses an LED, which is one type of semiconductor light source.

[0026] In the first embodiment, the light source distribution element 100 and the light distribution formation section 200 are integrally formed from a transparent material, and the boundary surface between the components is not a physical boundary surface but a virtual surface. However, when the light source distribution element 100 and the light distribution forming unit 200 are formed from different transparent materials, the exit surfaces 121a to 125a of the light source distribution element 100 are physically exposed surfaces, and when assembled with the light distribution forming unit 200, the exit surfaces 121a to 125a of the light source distribution element 100 are coupled to the light distribution forming unit 200.

[0027] In the first embodiment, the headlamp module is manufactured by injection molding and is made of a transparent material filled with a refractive material. The material from which the headlamp module is manufactured is preferably highly transparent from the viewpoint of light utilization efficiency, and is also preferably heat-resistant because the light source distribution element 100 is disposed immediately after the light source 1. For example, glass or a transparent resin such as silicone is suitable. Specifically, suitable transparent resins include acrylic resins (particularly PMMA: polymethyl methacrylate), polycarbonate (PC), and cycloolefin resins.

[0028] The light source distribution element 100 receives light from the light source 1 and has first to fifth exit surfaces 121a to 125a, the first to fifth exit surfaces 121a to 125a not overlapping in one direction (Z-axis direction) in a plane perpendicular to the optical axis of the light source 1 and in another direction (X-axis direction) perpendicular to the one direction, but are arranged in the other direction from one end side (+ side of the X-axis) to the other end side (- side of the X-axis) in the order of third exit surface 123a, second exit surface 122a, first exit surface 121a, fourth exit surface 124a, and fifth exit surface 125a, and guides the light incident from the light source 1 to the fifth exit surface.

[0029] The light source distribution element 100 comprises an input section 110 and a collective light guide section 120 . 8, incident section 110 is a collimator that has a conical shape and has lens 116 at the apex, and the bottom surface of the cone serves as the bonding surface for collecting light-guiding section 120. The bonding surface has a diameter of, for example, 20 mm. In the incident portion 110, light emitted from the light source 1 is incident on the lens 116, and the incident light is guided to the junction surface as parallel light, ideally as parallel light.

[0030] Of the light emitted from light source 1, light rays with small emission angles are incident on lens 116 and then directly guided to the conical bottom surface of incident section 110 (the joint surface of collective light-guiding section 120). On the other hand, of the light emitted from light source 1, light rays with large emission angles are incident on lens 116 and then reflected by reflecting surface 117 and guided to the conical bottom surface of incident section 110. The light rays directly guided from lens 116 and the light rays reflected and guided by reflecting surface 117 are guided to the joint surface of collective light-guiding section 120 as parallel light.

[0031] FIG. 9 shows the illuminance distribution at the joint surface of the light-source distribution element 100 when an LED that emits light elongated in the X-axis direction is used as the light source 1. In the first embodiment, as shown in FIG. 9 , the bonding surfaces of the light-source distribution element 100 are divided into equal lengths, i.e., equal widths, in one direction in a plane perpendicular to the optical axis of the light source 1, i.e., along the Z-axis direction, and include a first bonding surface 111 located at the center, a second bonding surface 112 and a third bonding surface 113 located in this order from the center to one end side in the one direction, i.e., on the + side of the Z-axis, and a fourth bonding surface 114 and a fifth bonding surface 115 located in this order from the center to the other end side in the one direction, i.e., on the - side of the Z-axis. The lengths of the first bonding surface 111 to the fifth bonding surface 115 may also be different from each other. The bonding surfaces, first bonding surface 111 to fifth bonding surface 115 are imaginary surfaces that indicate boundaries with collective light-guiding section 120 .

[0032] Collective light-guiding section 120 has a joint surface that joins with the joint surface of incident section 110. Collective light-guiding section 120 has first to fifth exit surfaces 121a to 125a that are arranged in a plane parallel to the joint surface of incident section 110, i.e., the ZX plane, and without overlapping in the Z-axis direction and the X-axis direction, and guides light from the joint surface of incident section 110 to first to fifth exit surfaces 121a to 125a. Along the X axis, fifth exit surface 125a, fourth exit surface 124a, first exit surface 121a, second exit surface 122a, and third exit surface 123a are arranged in this order from the other end side. Along the Z axis, fifth exit surface 125a, fourth exit surface 124a, first exit surface 121a, second exit surface 122a, and third exit surface 123a are arranged in this order from the other end side.

[0033] First to fifth exit surfaces 121a to 125a are rectangular and have the same length in the Z-axis direction. However, the lengths of the exit surfaces in the X-axis direction may be different. The length in the X-axis direction of first exit surface 121a is W, the length in the X-axis direction of second exit surface 122a and fourth exit surface 124a is W1 which is shorter than W, and the length in the X-axis direction of third exit surface 123a and fifth exit surface 125a is W2 which is shorter than W1. The relationship between W, W1, and W2 is W>W1>W2.

[0034] However, the lengths in the X-axis direction of the second exit surface 122a, the second light guiding section 122, the second focusing optical section 212, the second light distribution section 222, and the second projection lens 232 may be different from the lengths in the X-axis direction of the fourth exit surface 124a, the fourth light guiding section 124, the fourth focusing optical section 214, the fourth light distribution section 224, and the fourth projection lens 234. Similarly, the lengths in the X-axis direction of the third exit surface 123a, the third light guiding section 123, the third focusing optical section 213, the third light distribution section 223, and the third projection lens 233 may be different from the lengths in the X-axis direction of the fifth exit surface 125a, the fifth light guiding section 125, the fifth focusing optical section 215, the fifth light distribution section 225, and the fifth projection lens 235.

[0035] Collective light-guiding section 120 includes first light-guiding section 121 to fifth light-guiding section 125 . Each of the first light guiding section 121 to the fifth light guiding section 125 has a pair of opposing surfaces that face each other parallel to the X-axis direction in the ZX plane, a plane perpendicular to the optical axis of the light source 1, i.e., the Y-axis, and is a columnar body with a rectangular ZX cross section. First light guiding section 121 has first emission surface 121a and a pair of parallel opposing surfaces facing each other in the X-axis direction, and guides light from first bonding surface 111 of incident section 110 to first emission surface 121a.

[0036] First light guiding section 121 has a pair of opposing surfaces parallel to the Y axis, stands upright from first bonding surface 111 of incident section 110, and is formed integrally with incident section 110. The distance between the pair of opposing surfaces along the X axis direction is W, which is the same as the distance W between first emission surfaces 121a along the X axis direction. First light guiding section 121 has a rectangular parallelepiped shape that linearly connects first joint surface 111 of incident section 110 to first emission surface 121a. First light guiding section 121 causes light from first bonding surface 111 of incident section 110 to travel straight along the Y axis to first emission surface 121a, as shown as light beam L1 in FIGS.

[0037] Second light guiding section 122 has a pair of parallel opposing surfaces facing second emission surface 122a in the X-axis direction, and guides light from second bonding surface 112 of incident section 110 to second emission surface 122a. A pair of opposing surfaces of second light guiding section 122 has a pair of reflecting surfaces, that is, first reflecting surface 122b located on the central side in the X-axis direction and second reflecting surface 122c located on one end side. The opposing surface at one end in the X-axis direction of the pair of opposing surfaces in the second light-guiding section 122 has a second rising surface 122d that is perpendicular to the second bonding surface 112 from the bottom surface that contacts the second bonding surface 112 of the incident section 110, and a second reflecting surface 122c that is inclined 45 degrees toward one end with respect to the second bonding surface 112 from the upper side of the second rising surface 122d to the second exit surface 122a.

[0038] In other words, second light guiding section 122 is formed integrally with incident section 110 such that first reflecting surface 122b and second reflecting surface 122c are each inclined at 45 degrees toward one end with respect to the optical axis of light source 1. The first reflecting surface 122b is the entire surface of the opposing surface located on the central side in the X-axis direction. The distance between first reflecting surface 122b and second reflecting surface 122c along the X-axis direction is W1, which is the same as the distance W1 between second emitting surfaces 122a along the X-axis direction.

[0039] The length from the bottom to the top of second rising surface 122d corresponds to the length required to obtain an offset (W-W1) relative to length W1 of second exit surface 122a in the X-axis direction. The second light guiding section 122 is a columnar body formed integrally with the incident section 110 . Note that 45 degrees does not mean the exact angle of 45 degrees, but refers to a range of 45 degrees ±α that takes into account ±α in design tolerances, etc. In the following explanation, 45 degrees also refers to a range of 45 degrees ±α.

[0040] The angle at which the reflective surface is tilted does not have to be limited to 45 degrees. Since it is desirable for the reflective surface to be a total reflective surface, the ideal tilt angle is around 45 degrees. However, in the case of a mirror surface formed by metal deposition or the like, the tilt angle can be designed freely. However, it is desirable to make the reflective surface function as a total reflection surface. This is because a total reflection surface has a higher reflectivity than a mirror surface and contributes to improving the light utilization efficiency. In addition, by eliminating the mirror vapor deposition process, the manufacturing process of the light source distribution element 100 can be simplified, which contributes to reducing the manufacturing cost of the light source distribution element 100.

[0041] 10 to 12, second light guiding unit 122 guides light from second bonding surface 112 of incident unit 110 to second exit surface 122a by first reflecting surface 122b totally reflecting the light to second reflecting surface 122c, and then second reflecting surface 122c totally reflects the light to second exit surface 122a. Second light guiding unit 122 finally guides the light from second bonding surface 112 of incident unit 110 to second exit surface 122a as parallel light along the Y axis.

[0042] The amount of light totally reflected by the first reflecting surface 122b and totally reflected by the second reflecting surface 122c is comparable to that in the case where the second rising surface 122d is not provided, because there is no light from the second bonding surface 112 of the incident section 110 at both ends of the bonding surface of the second light-guiding section 122 that contacts the second bonding surface 112 of the incident section 110.

[0043] Third light guiding section 123 has a pair of parallel opposing surfaces facing third emission surface 123a in the X-axis direction, and guides light from third bonding surface 113 of incident section 110 to third emission surface 123a. A pair of opposing surfaces of third light guiding section 123 has a pair of reflecting surfaces, that is, third reflecting surface 123b located on the central side in the X-axis direction and fourth reflecting surface 123c located on one end side.

[0044] The opposing surface at one end in the X-axis direction of the pair of opposing surfaces in the third light-guiding section 123 has a fourth rising surface 123d that is perpendicular to the third bonding surface 113 from the bottom surface that contacts the third bonding surface 113 of the incident section 110, and a fourth reflecting surface 123c that is inclined 45 degrees toward one end with respect to the third bonding surface 113 from the upper side of the fourth rising surface 123d to the third exit surface 123a. In other words, third light guiding section 123 is formed integrally with incident section 110 such that third reflecting surface 123b and fourth reflecting surface 123c are each inclined at 45 degrees toward one end with respect to the optical axis of light source 1.

[0045] The third reflecting surface 123b is the entire surface of the opposing surface located on the central side in the X-axis direction. The distance between the third reflecting surface 123b and the fourth reflecting surface 123c along the X-axis direction is (W1+W2). As with the first reflecting surface 122b and the second reflecting surface 122c, the inclination angle of the third reflecting surface 123b and the fourth reflecting surface 123c does not have to be limited to 45 degrees.

[0046] The spacing W2 along the X-axis direction of the third exit surface 123a is the spacing (W1+W2) along the X-axis direction between the third reflecting surface 123b and the fourth reflecting surface 123c minus the spacing W1 along the X-axis direction between the first reflecting surface 122b and the second reflecting surface 122c in the second light-guiding section 122. The distance (W1+W2) along the X-axis direction between the third reflecting surface 123b and the fourth reflecting surface 123c of the third light guiding section 123 is shorter than 2W1, which is twice the distance W1 along the X-axis direction between the first reflecting surface 122b and the second reflecting surface 122c of the second light guiding section 122.

[0047] The length from the bottom to the top of the fourth rising surface 123d corresponds to the offset amount (W-W2) relative to the length W2 of the third exit surface 123a in the X-axis direction, in other words, the length required to obtain (2W-(W1+W2)). The third light guiding section 123 is a columnar body formed integrally with the incident section 110 .

[0048] 10 to 12, third light guiding unit 123 totally reflects light from third bonding surface 113 of incident unit 110 onto fourth reflecting surface 123c, which then totally reflects the light onto third exit surface 123a, thereby guiding the light to third exit surface 123a. Third light guiding unit 123 finally guides the light from third bonding surface 113 of incident unit 110 to third exit surface 123a as parallel light along the Y axis.

[0049] The amount of light totally reflected by the third reflecting surface 123b and totally reflected by the fourth reflecting surface 123c is comparable to that in the case where the fourth rising surface 123d is not provided, because there is no light from the third bonding surface 113 of the incident section 110 at both ends of the bonding surface of the third light-guiding section 123 that contacts the third bonding surface 113 of the incident section 110.

[0050] Third reflecting surface 123b of third light guiding section 123 is continuous with first reflecting surface 122b of second light guiding section 122 on one end side in the Z axis direction. Third light guiding section 123 is formed integrally with second light guiding section 122 from third joint surface 113 of incident section 110 to the position of first reflecting surface 122b of second light guiding section 122 to the position of second reflecting surface 122c. That is, the portion from third reflecting surface 123 b of third light guiding portion 123 to the position of second reflecting surface 122 c of second light guiding portion 122 is formed integrally with second light guiding portion 122 .

[0051] The fourth reflecting surface 123c of the third light guiding section 123 is located at a position away from the position of the second reflecting surface 122c of the second light guiding section 122 by the length W2 of the third exit surface 123a in the X-axis direction toward one end in the X-axis direction. That is, the distance along the X-axis direction between the third reflecting surface 123b and the fourth reflecting surface 123c is twice the distance W1 along the X-axis direction between the first reflecting surface 122b and the second reflecting surface 122c in the second light-guiding section 122, i.e., (W1+W2), which is shorter than 2W1.

[0052] The section from the position of the first reflecting surface 122b to the position of the second reflecting surface 122c of the second light guiding section 122 and the section from the position of the third reflecting surface 123b of the third light guiding section 123 to the position of the second reflecting surface 122c of the second light guiding section 122 form a common light guiding section in the Z-axis direction, with the shape of two second light guiding sections 122 arranged in parallel. From the position of the first reflecting surface 122b of the second light guiding section 122 to the position of the second reflecting surface 122c, the boundary surface between the second light guiding section 122 and the third light guiding section 123 is not a physical boundary surface, but a virtual surface.

[0053] Fourth light guiding section 124 has a pair of parallel opposing surfaces facing fourth emission surface 124a in the X-axis direction, and guides light from fourth bonding surface 114 of incident section 110 to fourth emission surface 124a. A pair of opposing surfaces of fourth light guiding section 124 has a pair of reflecting surfaces, that is, fifth reflecting surface 124b located on the central side in the X-axis direction and sixth reflecting surface 124c located on the other end side.

[0054] The opposing surface on the other end side in the X-axis direction of the pair of opposing surfaces in the fourth light-guiding section 124 has a sixth rising surface 124d that is perpendicular to the fourth bonding surface 114 from the bottom surface that contacts the fourth bonding surface 114 of the incident section 110, and has a sixth reflecting surface 124c that is inclined at 45 degrees toward the other end side with respect to the fourth bonding surface 114 from the upper side of the sixth rising surface 124d to the fourth emission surface 124a.

[0055] In other words, fourth light guiding section 124 is formed integrally with incident section 110 such that fifth reflecting surface 124b and sixth reflecting surface 124c are each inclined at 45 degrees toward one end with respect to the optical axis of light source 1. The sixth reflecting surface 124c is the entire surface of the opposing surface located on the central side in the X-axis direction. As with the first reflecting surface 122b and the second reflecting surface 122c, the angle of inclination of the fifth reflecting surface 124b and the sixth reflecting surface 124c does not have to be limited to 45 degrees.

[0056] The distance between the fifth reflecting surface 124b and the sixth reflecting surface 124c along the X-axis direction is W1, which is the same as the distance W1 between the fourth exit surface 124a along the X-axis direction. The length from the bottom to the top of the sixth rising surface 124d corresponds to the length required to obtain an offset (W-W1) relative to the length W1 of the fourth exit surface 124a in the X-axis direction. The fourth light guiding section 124 is a columnar body formed integrally with the incident section 110 .

[0057] 10 to 12 as light beam L4, the fourth light guiding unit 124 totally reflects the light from the fourth bonding surface 114 of the incident unit 110 to the sixth reflecting surface 124c, which then totally reflects the light to the fourth exit surface 124a, and guides the light to the fourth exit surface 124a. The fourth light guiding unit 124 finally guides the light from the fourth bonding surface 114 of the incident unit 110 to the fourth exit surface 124a as parallel light along the Y axis.

[0058] The amount of light totally reflected by the fifth reflecting surface 124b and totally reflected by the sixth reflecting surface 124c is comparable to that in the case where the sixth rising surface 124d is not provided, because there is no light from the fourth bonding surface 114 of the incident section 110 at both ends of the bonding surface of the fourth light-guiding section 124 that contacts the fourth bonding surface 114 of the incident section 110. The shape of fourth light guiding section 124 is in a line symmetric relationship with the shape of second light guiding section 122 with respect to the Y axis.

[0059] Fifth light guiding section 125 has a pair of parallel opposing surfaces facing fifth emission surface 125a in the X-axis direction, and guides light from fifth bonding surface 115 of incident section 110 to fifth emission surface 125a. A pair of opposing surfaces of fifth light guiding section 125 has a pair of reflecting surfaces, that is, seventh reflecting surface 125b located on the central side in the X-axis direction and eighth reflecting surface 125c located on the other end side.

[0060] The opposing surface on the other end side in the X-axis direction of the pair of opposing surfaces in the fifth light-guiding section 125 has an eighth rising surface 125d that is perpendicular to the fifth bonding surface 115 from the bottom surface that contacts the fifth bonding surface 115 of the incident section 110, and has an eighth reflecting surface 125c that is inclined 45 degrees toward the other end side with respect to the fifth bonding surface 115 from the upper side of the eighth rising surface 125d to the fifth exit surface 125a. In other words, fifth light guiding section 125 is formed integrally with incident section 110 such that seventh reflecting surface 125b and eighth reflecting surface 125c are each inclined at 45 degrees toward one end with respect to the optical axis of light source 1.

[0061] As with the first reflecting surface 122b and the second reflecting surface 122c, the angle of inclination of the seventh reflecting surface 125b and the eighth reflecting surface 125c does not have to be limited to 45 degrees. The eighth reflecting surface 125c is the entire surface of the opposing surface located on the central side in the X-axis direction. The distance between the seventh reflecting surface 125b and the eighth reflecting surface 125c along the X-axis direction is (W1+W2).

[0062] The spacing W2 of the fifth exit surface 125a along the X-axis direction is the value obtained by subtracting the spacing W1 along the X-axis direction between the fifth reflecting surface 124b and the sixth reflecting surface 124c in the fourth light-guiding section 124 from the spacing (W1+W2) between the seventh reflecting surface 125b and the eighth reflecting surface 125c along the X-axis direction. The distance (W1+W2) along the X-axis direction between the seventh reflecting surface 125b and the eighth reflecting surface 125c of the fifth light guiding section 125 is shorter than 2W1, which is twice the distance W1 along the X-axis direction between the fifth reflecting surface 124b and the sixth reflecting surface 124c of the fourth light guiding section 124.

[0063] The length from the bottom to the top of the eighth rising surface 125d corresponds to the offset amount (W-W2) relative to the length W2 of the fifth exit surface 125a in the X-axis direction, in other words, the length required to obtain (2W-(W1+W2)). Fifth light guiding section 125 is a columnar body formed integrally with incident section 110 .

[0064] 10 to 12, the fifth light guiding unit 125 guides the light from the fifth bonding surface 115 of the incident unit 110 to the fifth exit surface 125a by the seventh reflecting surface 125b totally reflecting the light to the eighth reflecting surface 125c, which then totally reflects the light to the fifth exit surface 125a, as shown as light beam L5 in Fig. 10 to 12. The fifth light guiding unit 125 finally guides the light from the fifth bonding surface 115 of the incident unit 110 to the fifth exit surface 125a as parallel light along the Y axis.

[0065] The amount of light totally reflected by the seventh reflecting surface 125b and totally reflected by the eighth reflecting surface 125c is comparable to that in the case where the eighth rising surface 125d is not provided, because there is no light from the fifth bonding surface 115 of the incident section 110 at both ends of the bonding surface of the fifth light-guiding section 125 that contacts the fifth bonding surface 115 of the incident section 110.

[0066] Seventh reflecting surface 125b of fifth light guiding section 125 is continuous with fifth reflecting surface 124b of fourth light guiding section 124 on the other end side in the Z-axis direction. Fifth light guiding section 125 is formed integrally with fourth light guiding section 124 from fifth joint surface 115 of incident section 110 to the position of fifth reflecting surface 124b of fourth light guiding section 124 to the position of sixth reflecting surface 124c. That is, the portion from seventh reflecting surface 125b of fifth light guiding portion 125 to the position of sixth reflecting surface 124c of fourth light guiding portion 124 is formed integrally with fourth light guiding portion 124.

[0067] The eighth reflecting surface 125c of the fifth light guiding section 125 is located at a position away from the position of the sixth reflecting surface 124c of the fourth light guiding section 124 by the length W2 of the fifth exit surface 125a in the X-axis direction toward the other end in the X-axis direction. That is, the distance along the X-axis direction between the seventh reflecting surface 125b and the eighth reflecting surface 125c is twice the distance W1 along the X-axis direction between the fifth reflecting surface 124b and the sixth reflecting surface 124c in the fourth light-guiding section 124, that is, (W1+W2) which is shorter than 2W1.

[0068] The section from the position of the fifth reflecting surface 124b to the position of the sixth reflecting surface 124c of the fourth light guiding section 124 and the section from the position of the seventh reflecting surface 125b of the fifth light guiding section 125 to the position of the sixth reflecting surface 124c of the fourth light guiding section 124 form a common light guiding section in the Z-axis direction, with two fourth light guiding sections 124 arranged in parallel. From the position of the fifth reflecting surface 124b of the fourth light guiding section 124 to the position of the sixth reflecting surface 124c, the boundary surface between the fourth light guiding section 124 and the fifth light guiding section 125 is not a physical boundary surface, but a virtual surface.

[0069] In the light source distribution element 100 configured in this manner, the output surface of the collective light guide section 120 has first output surface 121a to fifth output surface 125a, which allows the length of the side in the Z-axis direction of the output surface of the collective light guide section 120 to be reduced without reducing the light utilization efficiency of the light from the light source 1. This will be explained. The apparent size of a light source is defined by "Abbe's invariant," which is determined by the product of the divergence angle in a direction of the light source and the length of the side of the light source in that direction. In other words, if the height of the light source, i.e., the vertical length, is h0, the vertical divergence angle of the light from the light source is θ0, the vertical length of the exit surface, i.e., the length of the vertical side, is h1, and the vertical divergence angle of the light emitted from the exit surface is θ1, then the relationship is h0×sin θ0>h1×sin θ1.

[0070] Therefore, by dividing the light beam from light source 1 into multiple beams, the apparent height of the light source can be reduced. In embodiment 1, first light guiding section 121 to fifth light guiding section 125 divide the light from light source 1 collimated by incident section 110 into five light beams, so that the length of the side in the Z-axis direction of the exit surface of collective light guiding section 120 can be reduced, and the length of the side in the Z-axis direction of first exit surface 121a to fifth exit surface 125a can be reduced. In the headlight module according to the first embodiment, the height of the projection surface can be reduced, and the headlight module can be made thinner and more compact.

[0071] The light distribution forming section 200 has a first projection surface 231a to a third projection surface 233a positioned along the X-axis direction, and totally reflects light in the Y-axis direction from the exit surfaces (first exit surface 121a to fifth exit surface 125a) in the collective light-guiding section 120 of the light-source distribution element 100 forward and downward in the Z-axis direction, and guides the light from the first projection surface 231a to the third projection surface 233a. The light distribution forming unit 200 includes a light collecting optical unit 210, a light collecting distribution unit 220, and a projection unit 230. The light distribution forming unit 200 is integrally formed from a transparent material.

[0072] The collective light-collecting optical unit 210 collects light from the exit surfaces (first exit surface 121a to fifth exit surface 125a) of the collective light-guiding unit 120 by totally reflecting the light downward and forward in the Z-axis direction. The collective light-collecting optical unit 210 is formed integrally with the collective light-guiding unit 120. The collective focusing optic 210 comprises a first focusing optic 211 to a fifth focusing optic 215 . The first focusing optical unit 211 to the fifth focusing optical unit 215 are arranged along the X-axis in the order of the fifth focusing optical unit 215, the fourth focusing optical unit 214, the first focusing optical unit 211, the second focusing optical unit 212, and the third focusing optical unit 213 from the other end side.

[0073] The first light-collecting optical unit 211 has a joint surface that joins with the first exit surface 121a of the first light-guiding unit 121, a reflecting surface that faces the joint surface, is inclined toward one end of the Z axis, i.e., forward, relative to the joint surface, and has a light-collecting function, a pair of parallel opposing surfaces along the X axis, and a front surface that is located on one end of the Z axis and serves as an exit port for light reflected by the reflecting surface. The length along the X-axis of the joint surface of the first focusing optical unit 211, the distance between a pair of opposing surfaces of the first focusing optical unit 211, and the length along the X-axis of the front surface of the first focusing optical unit 211 are W, which is the same as the length W of the first exit surface 121a in the X-axis direction.

[0074] In the first light collecting optical unit 211, the reflecting surface is a flat surface inclined forward at an angle of less than 45 degrees relative to the bonding surface, and may be a curved surface depending on the application. First light-collecting optical unit 211 collects light from first emission surface 121a of first light-guiding unit 121 by total reflection by the reflecting surface, downward and forward in the Z-axis direction. The joint surface of first light collecting optical unit 211 and first emission surface 121a of first light guiding unit 121 are not physically joined surfaces but are virtual surfaces.

[0075] The second light-collecting optical unit 212 has a joint surface that joins with the second emission surface 122a of the second light-guiding unit 122, a reflecting surface that faces the joint surface, is inclined toward one end of the Z axis, i.e., forward, relative to the joint surface, and has a light-collecting function, a pair of parallel opposing surfaces along the X axis, and a front surface that is located on one end of the Z axis and serves as an exit for light reflected by the reflecting surface. The length along the X-axis of the joint surface of the second focusing optical unit 212, the distance between a pair of opposing surfaces of the second focusing optical unit 212, and the length along the X-axis of the front surface of the second focusing optical unit 212 are W1, which is the same as the length W1 in the X-axis direction of the second exit surface 122a.

[0076] In the second light collecting optical section 212, the reflecting surface is a flat surface inclined forward at an angle of less than 45 degrees relative to the bonding surface, and may be a curved surface depending on the application. The second light-collecting optical unit 212 collects light from the second light-emitting surface 122a of the second light-guiding unit 122 by total reflection by the reflecting surface in a downward forward direction in the Z-axis direction. The joint surface of second light collecting optical unit 212 and second emission surface 122a of second light guiding unit 122 are not physically joined surfaces but are virtual surfaces.

[0077] The third light-collecting optical unit 213 has a joint surface that joins with the third exit surface 123a of the third light-guiding unit 123, a reflecting surface that faces the joint surface and is inclined toward one end of the Z axis, i.e., forward, relative to the joint surface, and has a light-collecting function, a pair of parallel opposing surfaces along the X axis, and a front surface that is located on one end of the Z axis and serves as an exit for light reflected by the reflecting surface. The length along the X-axis of the joint surface of the third focusing optical unit 213, the distance between a pair of opposing surfaces of the third focusing optical unit 213, and the length along the X-axis of the front surface of the third focusing optical unit 213 are W2, which is the same as the length W2 in the X-axis direction of the third exit surface 123a.

[0078] In the third light collecting optical section 213, the reflecting surface is a flat surface inclined forward at an angle of less than 45 degrees relative to the bonding surface, and may be a curved surface depending on the application. The reflecting surface of the third light-collecting optical unit 213 is tilted in the negative direction of the X-axis, that is, towards the second projection lens 232. The third light-collecting optical unit 213 collects light from the third emission surface 123a of the third light-guiding unit 123 by total reflection downwards toward the center and forward in the Z-axis direction using the reflecting surface. In the first embodiment, the joint surface of third light collecting optical unit 213 and third emission surface 123a of third light guiding unit 123 are not physically joined surfaces but are virtual surfaces.

[0079] The fourth light-collecting optical unit 214 has a joint surface that joins with the fourth exit surface 124a of the fourth light-guiding unit 124, a reflecting surface that faces the joint surface and is inclined toward one end of the Z axis, i.e., forward, relative to the joint surface, and has a light-collecting function, a pair of parallel opposing surfaces along the X axis, and a front surface located on one end of the Z axis that serves as an exit for light reflected by the reflecting surface. The length along the X-axis of the joint surface of the fourth focusing optical unit 214, the distance between a pair of opposing surfaces of the fourth focusing optical unit 214, and the length along the X-axis of the front surface of the fourth focusing optical unit 214 are W1, which is the same as the length W1 in the X-axis direction of the fourth exit surface 124a.

[0080] In the fourth light collecting optical section 214, the reflecting surface is a flat surface inclined forward at less than 45 degrees relative to the bonding surface, and may be a curved surface depending on the application. The fourth light-collecting optical unit 214 collects light from the fourth emission surface 124a of the fourth light-guiding unit 124 by total reflection by the reflecting surface in a forward downward direction in the Z-axis direction. In the first embodiment, the bonding surface of the fourth light collecting optical unit 214 and the fourth emission surface 124a of the fourth light guiding unit 124 are not physically bonded surfaces but are virtual surfaces.

[0081] The fifth light-collecting optical unit 215 has a joint surface that joins with the fifth exit surface 125a of the fifth light-guiding unit 125, a reflecting surface that faces the joint surface and is inclined toward one end of the Z axis, i.e., forward, relative to the joint surface, and has a light-collecting function, a pair of opposing surfaces along the X axis, and a front surface that is located on one end of the Z axis and serves as an exit for light reflected by the reflecting surface. The length along the X-axis of the joint surface of the fifth focusing optical unit 215, the distance between a pair of opposing surfaces of the fifth focusing optical unit 215, and the length along the X-axis of the front surface of the fifth focusing optical unit 215 are W2, which is the same as the length W2 in the X-axis direction at the fifth exit surface 125a.

[0082] In the fifth light collecting optical unit 215, the reflecting surface is a flat surface inclined forward at less than 45 degrees relative to the cemented surface, and may be a curved surface depending on the application. The reflecting surface of the fifth light-collecting optical unit 215 is tilted in the positive direction of the X axis, that is, toward the third projection lens 233. Fifth light-collecting optical unit 215 collects light from fifth emission surface 125a of fifth light-guiding unit 125 by total reflection downwards at the reflecting surface so that the light is directed forward in the Z-axis direction and toward the center. In the first embodiment, the joint surface of fifth light collecting optical section 215 and fifth emission surface 125a of fifth light guiding section 125 are not physically joined surfaces but are virtual surfaces.

[0083] By making the reflecting surfaces of each of the first focusing optical unit 211 to the fifth focusing optical unit 215 reflecting surfaces having a focusing function, it is possible to easily form the complex light distribution required for a headlamp device.

[0084] The light collecting and distributing section 220 guides the light beams (first light beam L1 to fifth light beam L5) collected by total reflection by the light collecting and concentrating optical section 210 to the projection surfaces (first projection surface 231a to third projection surface 233a). The light collecting and distributing section 220 is formed integrally with the light collecting and concentrating optical section 210 . The collective light distribution section 220 has a cutoff line forming surface 220a on its bottom surface, i.e., the surface located on the side of the incident section 110 in the Y-axis direction, which has a ridge line for forming a cutoff line along the X-axis direction, and the section from the ridge line of the cutoff line forming surface 220a to the front surface of the collective light-collecting optical section 210 is the first region section 220A, and the section from the ridge line of the cutoff line forming surface 220a to the projection section 230 is the second region section 220B.

[0085] In the first region 220A, the bottom surface is a horizontal surface along the ZX plane, and the top surface opposite the bottom surface is also a horizontal surface along the ZX plane. In order to form a cutoff line, the bottom surface may be a surface that is inclined in the Z-axis direction relative to the ZX plane, and the top surface may also be a surface that is inclined in the Z-axis direction relative to the ZX plane. Furthermore, at least one of the bottom surface and the top surface may be changed to a surface parallel to the ZX plane. The first region 220A has a cutoff line forming surface 220a, which is a reflective surface, on its bottom surface.

[0086] The collective light distribution unit 220 totally reflects light from the front surface of the collective light collecting optical unit 210 by the cutoff line forming surface 220a, which is a reflective surface, and propagates the light with a cutoff line formed thereon to the projection unit 230 via the second area unit 220B. 13 shows the optical path of light totally reflected forward and downward in the Z-axis direction by the reflecting surface of the first light collecting optical unit 211, and the collected light distribution unit 220 reflects a portion of the light on the cutoff line forming surface 221a to guide it to the first projection surface 231a, and guides the remaining light directly to the first projection surface 231a. As a result, a cutoff light distribution is projected from the first projection surface 231a. The bottom and top surfaces of the second region 220B are horizontal surfaces along the ZX plane, like the bottom and top surfaces of the first region 220A, but may be surfaces that are inclined toward the Z-axis direction relative to the ZX plane, or surfaces that are parallel to the ZX plane.

[0087] The collective light distribution section 220 includes a first light distribution section 221 to a fifth light distribution section 225 . The first to fifth light distribution sections 221 to 225 are arranged along the X axis in the order of fifth light distribution section 225, fourth light distribution section 224, first light distribution section 221, second light distribution section 222, and third light distribution section 223 from the other end side, and are integrally formed. Adjacent light distribution sections are not physically joined. The opposing surfaces of adjacent light distribution sections are virtual surfaces.

[0088] The first light distribution section 221 guides the light of the luminous flux L1 that is totally reflected and collected by the front surface of the first light collecting optical section 211 to a first projection surface 231a of a first projection lens 231 in the projection section 230. The joint surface between first light distribution section 221 and the front surface of first light collecting optical section 211 is not a physically joined surface, but a virtual surface. The width of first light distribution section 221 along the X axis is W, which is the same as the length W of first emission surface 121a in the X axis direction.

[0089] The first light distribution unit 221 has a first cutoff line forming surface 221a having a ridge line for forming a cutoff line along the X-axis direction. The first region 221A is the region from the ridge line of the first cutoff line forming surface 221a to the front surface of the first light collecting optical unit 211, and the second region 221B is the region from the ridge line of the first cutoff line forming surface 221a to the first projection lens 231.

[0090] In the first region 221A, the bottom surface is located on the incident portion 110 side and is a horizontal plane along the ZX plane. The top surface is also a horizontal plane along the ZX plane. The bottom surface of the first region 221A has a first cutoff line forming surface 221a, which is a reflective surface. The length in the X-axis direction of a pair of opposing surfaces that face each other parallel to the X-axis direction, i.e., the distance between them, is W. A portion of the light beam L1 from the front surface of the first light collecting optical unit 211 is reflected by the first cutoff line forming surface 221a. The light reflected by the first cutoff line forming surface 221a and having a cutoff line formed thereon is guided to the first projection lens 231 via the second area 221B.

[0091] Furthermore, the remaining light of the light beam L1 from the front surface of the first light-collecting optical unit 211 is not reflected by the first cutoff line forming surface 221a and is guided directly to the first projection lens 231 via the second area 221B. The light reflected by the first cutoff line forming surface 221a and the light not reflected by the first cutoff line forming surface 221a are combined to form a cutoff light distribution, which is projected as a low beam from the first projection lens 231.

[0092] The second light distribution section 222 guides the light of the luminous flux L2 that is totally reflected and collected by the front surface of the second light collecting optical section 212 to the second projection surface 232a of the projection section 230. The joint surface between second light distribution section 222 and the front surface of second light collection optical section 212 is not a physically joined surface, but a virtual surface. The width of second light distribution section 222 along the X axis is W1, which is the same as the length W1 of second emission surface 122a in the X axis direction.

[0093] The second light distribution unit 222 has a second cutoff line forming surface 222a having a ridge line for forming a cutoff line along the X-axis direction. The first region 222A is the region from the ridge line of the second cutoff line forming surface 222a to the front surface of the second concentrating optical unit 212, and the second region 222B is the region from the ridge line of the second cutoff line forming surface 222a to the second projection lens 232.

[0094] In the first region 222A, the bottom surface is located on the incident portion 110 side and is a horizontal plane along the ZX plane. The top surface is also a horizontal plane along the ZX plane. The bottom surface of the first region 222A has a second cutoff line forming surface 222a, which is a reflective surface. The length in the X-axis direction of a pair of opposing surfaces facing each other in parallel to the X-axis direction, that is, the distance therebetween, is W1. A portion of the light beam L2 from the front surface of the second converging optical unit 212 is reflected by the second cutoff line forming surface 222a. The light reflected by the second cutoff line forming surface 222a and having a cutoff line formed thereon is guided to the second projection lens 232 via the second region 222B.

[0095] Furthermore, the remaining light of the light beam L2 from the front surface of the second light-collecting optical unit 212 is not reflected by the second cutoff line forming surface 222a and is guided directly to the second projection lens 232 via the second area 222B. The light reflected by the second cutoff line forming surface 222a and the light not reflected by the first cutoff line forming surface 222a are combined to form a cutoff light distribution, which is projected as a low beam from the second projection lens 232.

[0096] The third light distribution unit 223 guides light of the luminous flux L3 that is totally reflected and collected from the front surface of the third light collecting optical unit 213 to the second projection surface 232a of the projection unit 230. The joint surface between the third light distribution unit 223 and the front surface of the third light collecting optical unit 213 is not a physically joined surface, but a virtual surface. As the third light distribution section 223 approaches the second projection surface 232a, it overlaps with the second light distribution section 222, and the overlapping portion becomes a common portion.

[0097] The third light distribution unit 223 has a third cutoff line forming surface 223a having a ridge line for forming a cutoff line along the X-axis direction. The first region 223A is the region from the ridge line of the third cutoff line forming surface 223a to the front surface of the third light collecting optical unit 213, and the second region 223B is the region from the ridge line of the third cutoff line forming surface 223a to the second projection lens 232.

[0098] In the first region 223A, the bottom surface is located on the incident portion 110 side and is a horizontal plane along the ZX plane. The top surface is also a horizontal plane along the ZX plane. The bottom surface of the first region 223A has a third cutoff line forming surface 223a, which is a reflective surface. The length in the X-axis direction of a pair of opposing surfaces that face each other parallel to the X-axis direction, i.e., the distance between them, is W2. The first area portion 223A overlaps with the first area portion 222A at the center, and the overlapping portion is a common portion.

[0099] The second area 223B overlaps with the second area 222B at the center, and the overlapping portion is a common portion, with the joint surface with the second projection lens 232 being located at the center of the joint surface with the second projection lens 232 in the second area 222B, at width W2. The boundary between the third light distribution section 223 and the second light distribution section 222 is virtual, and the third light distribution section 223 indicates the optical path of light of the luminous flux L3 from the third focusing optical section 213, and the second light distribution section 222 indicates the optical path of light of the luminous flux L2 from the second focusing optical section 212.

[0100] A portion of the light beam L3 from the front surface of the third converging optical unit 213 is reflected by the third cutoff line forming surface 223a. The light reflected by the third cutoff line forming surface 223a and having a cutoff line formed thereon is guided to the second projection lens 232 via the second region 223B. Furthermore, the remaining light of the light beam L3 from the front surface of the third converging optical unit 213 is not reflected by the third cutoff line forming surface 223a and is guided directly to the second projection lens 232 via the second area 223B.

[0101] The light reflected by the third cutoff line forming surface 223a and the light not reflected by the third cutoff line forming surface 223a are combined to form a cutoff light distribution, which is projected as a low beam from the second projection lens 232. The light of the light beam L3 is combined with the light beam L2 guided from the second light distribution section 222 and projected from the second projection lens 232 as a low beam.

[0102] The fourth light distribution unit 224 guides the light of the luminous flux L4 that is totally reflected and collected from the front surface of the fourth light collecting optical unit 214 to the third projection surface 233a of the projection unit 230. The joint surface between the fourth light distribution unit 224 and the front surface of the fourth light collecting optical unit 214 is not a physically joined surface, but a virtual surface. The width of fourth light distribution section 224 along the X axis is W1, which is the same as the length W1 of fourth emission surface 124a in the X axis direction.

[0103] The fourth light distribution unit 224 has a fourth cutoff line forming surface 224a having a ridge line for forming a cutoff line along the X-axis direction. The first region 224A is the region from the ridge line of the fourth cutoff line forming surface 224a to the front surface of the fourth light collecting optical unit 214, and the second region 224B is the region from the ridge line of the fourth cutoff line forming surface 224a to the third projection lens 233.

[0104] In the first region 224A, the bottom surface is located on the incident portion 110 side and is a horizontal plane along the ZX plane. The top surface is also a horizontal plane along the ZX plane. The bottom surface of the first region 224A has a fourth cutoff line forming surface 224a, which is a reflective surface. The length in the X-axis direction of a pair of opposing surfaces that face each other parallel to the X-axis direction, i.e., the distance between them, is W1. A portion of the light beam L4 from the front surface of the fourth converging optical unit 214 is reflected by the fourth cutoff line forming surface 224a. The light reflected by the fourth cutoff line forming surface 224a and having a cutoff line formed thereon is guided to the third projection lens 233 via the second region 224B.

[0105] Furthermore, the remaining light of the light beam L4 from the front surface of the fourth converging optical unit 214 is not reflected by the fourth cutoff line forming surface 224a and is guided directly to the third projection lens 233 via the second area 224B. The light reflected by the fourth cutoff line forming surface 224a and the light not reflected by the fourth cutoff line forming surface 224a are combined to form a cutoff light distribution, which is projected as a low beam from the third projection lens 233.

[0106] Fifth light distribution unit 225 guides light of luminous flux L5 that is totally reflected and collected from the front surface of fifth light collecting optical unit 215 to third projection surface 233a of projection unit 230. The joint surface between fifth light distribution unit 225 and the front surface of fifth light collecting optical unit 215 is not a physically joined surface, but a virtual surface. As fifth light distribution section 225 approaches third projection surface 233a, it overlaps with fourth light distribution section 224, and the overlapping portion becomes a common portion.

[0107] The fifth light distribution unit 225 has a fifth cutoff line forming surface 225a having a ridge line for forming a cutoff line along the X-axis direction. The first region 225A is the area from the ridge line of the fifth cutoff line forming surface 225a to the front surface of the fifth concentrating optical unit 215, and the second region 225B is the area from the ridge line of the fifth cutoff line forming surface 225a to the fifth projection lens 235.

[0108] In the first region 225A, the bottom surface is located on the incident portion 110 side and is a horizontal plane along the ZX plane. The top surface is also a horizontal plane along the ZX plane. The bottom surface of the first region 225A has a fifth cutoff line forming surface 225a, which is a reflective surface. The length in the X-axis direction of a pair of opposing surfaces that face each other parallel to the X-axis direction, i.e., the distance between them, is W2. The first area portion 225A overlaps with the first area portion 224A at the center, and the overlapping portion is a common portion.

[0109] The second region 225B overlaps with the second region 224B at the center, and the overlapping portion is a common portion, with the joint surface with the third projection lens 233 being located at the center of the joint surface with the third projection lens 233 in the second region 224B, at width W2. The boundary between the fifth light distribution section 225 and the fourth light distribution section 224 is virtual, and the fifth light distribution section 225 indicates the optical path of light of the luminous flux L5 from the fifth focusing optical section 215, and the fourth light distribution section 224 indicates the optical path of light of the luminous flux L4 from the fourth focusing optical section 214.

[0110] A portion of the light of the light beam L5 from the front surface of the fifth converging optical unit 215 is reflected by the fifth cutoff line forming surface 225a. The light reflected by the fifth cutoff line forming surface 225a and having a cutoff line formed thereon is guided to the third projection lens 233 via the second region 225B. In addition, the remaining light of the light beam L5 from the front surface of the fifth converging optical unit 215 is not reflected by the fifth cutoff line forming surface 225a and is guided directly to the third projection lens 233 via the second area 225B.

[0111] The light reflected by the fifth cutoff line forming surface 225a and the light not reflected by the fifth cutoff line forming surface 225a are combined to form a cutoff light distribution, which is projected as a low beam from the third projection lens 233. The light of the light beam L5 is combined with the light beam L4 guided from the fourth light distribution section 224 and projected from the third projection lens 233 as a low beam.

[0112] The ridge line for forming the cutoff line of each of the cutoff line forming surfaces 221a to 225a is the underline at the joint surface between each of the first region portions 221A to 225A and each of the second region portions 221B to 225B, that is, the front end edge of the cutoff line forming surfaces 221a to 225a on the bottom surface of each of the first region portions 221A to 225A. The ridge line for forming the cutoff line is positioned so that the upper side, i.e., the outside of the light distribution pattern, is dark and the lower side, i.e., the inside of the light distribution pattern, is bright.

[0113] Projection unit 230 has first to third projection surfaces 231a to 233a, and projects light guided as a luminous flux by collective light distribution unit 220 from first to third projection surfaces 231a to 233a. Projection unit 230 is formed integrally with collective light distribution unit 220. The projection unit 230 includes a first projection lens 231 to a third projection lens 233 . The first to third projection lenses 231 to 233 are arranged along the X axis in the order of the third projection lens 233, the first projection lens 231, and the second projection lens 232 from the other end side.

[0114] The first projection lens 231 has a first projection surface 231a, and projects the light guided as the light beam L1 by the first light distribution section 221 forward from the first projection surface 231a as low beam irradiation light. The first projection lens 231 is a convex lens having a first projection surface 231a with a convex shape on its surface. By aligning the focal point of the convex lens with the ridge line of the first cutoff line forming surface 221a, the formed cutoff light distribution can be projected. The surface of the first projection lens 231 may be a concave lens.

[0115] The joint surface between the first projection lens 231 and the first light distribution section 221 is not a physically joined surface, but a virtual surface. The length of the first projection lens 231 in the X-axis direction is W, which is the same as the interval W of the first emission surfaces 121a along the X-axis direction.

[0116] The second projection lens 232 has a second projection surface 232a, and combines the light guided as light beam L2 by the second light distribution section 222 and the light guided as light beam L3 by the third light distribution section 223, and projects the combined light forward from the second projection surface 232a as low beam illumination light. The second projection lens 232 is a convex lens having a second projection surface 232a with a convex shape on its surface. By aligning the focal point of the convex lens with the ridge line of the second cutoff line forming surface 222a, the formed cutoff light distribution can be projected. The surface of the second projection lens 232 may be a concave lens.

[0117] The joint surfaces between the second projection lens 232 and the second and third light distribution sections 222 and 223 are not physically joined surfaces but are virtual surfaces. The length of the second projection lens 232 in the X-axis direction is W1, which is the same as the interval W1 along the X-axis direction of the second emission surface 122a.

[0118] The third projection lens 233 has a third projection surface 233a, and combines the light guided as light beam L4 by the fourth light distribution section 224 and the light guided as light beam L5 by the fifth light distribution section 225, and projects the combined light forward from the third projection surface 233a as low beam illumination light. The third projection lens 233 is a convex lens having a third projection surface 233a with a convex shape on its surface. By aligning the focal point of the convex lens with the ridge line of the fourth cutoff line forming surface 224a, the formed cutoff light distribution can be projected. The surface of the third projection lens 233 may be a concave lens.

[0119] The joint surfaces between the third projection lens 233 and the fourth and fifth light distribution sections 224 and 225 are not physically joined surfaces but are virtual surfaces. The length of the third projection lens 233 in the X-axis direction is W1, which is the same as the interval W1 along the X-axis direction of the fourth exit surface 124a.

[0120] The total length in the X-axis direction of the first to third projection surfaces 231a to 233a, which are arranged in a line along the X-axis, is (W+2W1). When a first projection surface to a fifth projection surface are provided for each of the first exit surface 121a to the fifth exit surface 125a, and the length of each of the first projection surface to the fifth projection surface in the X-axis direction is W, the total length of the first projection surface to the fifth projection surface in the X-axis direction is 5W, which is 4W-2W1 shorter in the first embodiment. Each of the first projection lens 231 to the third projection lens 233 may be a concave lens having a concave projection surface on its surface.

[0121] Next, the path of light from the bonding surface of the incident portion 110 will be described with reference to FIGS. The light guided from the first bonding surface 111 of the incident section 110 to the first light guiding section 121 travels straight along the Y axis to the first exit surface 121a, as shown as light beam L1 in Figures 10 to 12, and the light that reaches the reflecting surface of the first focusing optical section 211 is totally reflected by the reflecting surface of the first focusing optical section 211 and focused forward and downward in the Z axis direction, and propagates within the first light distribution section 221.

[0122] In the first light distribution section 221, the light of the light beam L1 from the front surface of the first focusing optical section 211 is totally reflected by the first cutoff line forming surface 221a, and the light of the light beam L1 having a cutoff line formed thereon is guided to the first projection lens 231 via the second area section 221B. The light beam L1 that has reached the first projection lens 231 and has a cutoff line formed therein is converged by the first projection lens 231 and emitted forward as low beam irradiation light.

[0123] The light guided from the second bonding surface 112 of the incident section 110 to the second light guiding section 122 travels straight along the Y axis to the first reflecting surface 122b, as shown as light beam L2 in Figures 10 to 12, and the light that reaches the first reflecting surface 122b is totally reflected by the first reflecting surface 122b at a right angle to one end side in the X axis direction. The light that is totally reflected at a right angle by the first reflecting surface 122b and reaches the second reflecting surface 122c is totally reflected at a right angle by the second reflecting surface 122c, is guided along the Y axis to the second exit surface 122a, and reaches the reflecting surface of the second focusing optical unit 212.

[0124] The light that reaches the reflecting surface of the second focusing optical unit 212 is totally reflected by the reflecting surface of the second focusing optical unit 212 forward in the Z-axis direction and downward, where it is focused, and propagates within the second light distribution unit 222. In the second light distribution section 222, the light of the light beam L2 from the front surface of the second focusing optical section 212 is totally reflected by the second cutoff line forming surface 222a, and the light of the light beam L2 on which a cutoff line is formed is guided to the second projection lens 232 via the second area section 222B. The light beam L2, which has reached the second projection lens 232 and has a cutoff line formed therein, is converged by the second projection lens 232 and emitted forward as low beam irradiation light.

[0125] The light guided from the third bonding surface 113 of the incident portion 110 to the third light guiding portion 123 travels straight along the Y axis to the third reflecting surface 123b, as shown as light beam L3 in Figures 10 to 12, and the light that reaches the third reflecting surface 123b is totally reflected by the third reflecting surface 123b at a right angle to one end side in the X axis direction. The light that is totally reflected at a right angle by the third reflecting surface 123b and reaches the fourth reflecting surface 123c is totally reflected at a right angle by the fourth reflecting surface 123c, is guided along the Y axis to the third exit surface 123a, and reaches the reflecting surface of the third focusing optical unit 213.

[0126] A portion of the light that reaches the reflecting surface of the third focusing optical unit 213 is totally reflected by the reflecting surface of the third focusing optical unit 213 and focused forward in the Z-axis direction and downward toward the center, and then propagates within the third light distribution unit 223. In the third light distribution unit 223, a portion of the light of the light beam L3 from the front surface of the third light collecting optical unit 213 is totally reflected by the third cutoff line forming surface 223a. The light of the light beam L3 that has been reflected by the third cutoff line forming surface 223a and has a cutoff line formed thereon is guided to the second projection lens 232 via the second region 223B.

[0127] In addition, the remaining light that reaches the reflecting surface of the third focusing optical unit 213 is totally reflected by the reflecting surface of the second focusing optical unit 213 and focused forward in the Z-axis direction and downward toward the center, and then propagates within the second light distribution unit 222. In the second light distribution unit 222, the remaining light of the light beam L3 from the front surface of the third light collecting optical unit 213 is reflected by the second cutoff line forming surface 222a. The light of the light beam L3, which has been reflected by the second cutoff line forming surface 222a and has a cutoff line formed thereon, is guided to the second projection lens 232 via the second region 223B. The light of the light beam L3, which has reached the second projection lens 232 and has a cutoff line formed thereon, is combined with the light of the light beam L2, which has been guided from the second light distribution section 222 by the second projection lens 232 and has a cutoff line formed thereon, and is then focused and emitted forward as low beam illumination light.

[0128] The light guided from the fourth bonding surface 114 of the incident section 110 to the fourth light-guiding section 124 travels straight along the Y-axis to the fifth reflecting surface 124b, as shown as light beam L4 in Figures 10 to 12, and the light that reaches the fifth reflecting surface 124b is totally reflected by the fifth reflecting surface 124b at a right angle to the other end side in the X-axis direction. The light that is totally reflected at a right angle by the fifth reflecting surface 124b and reaches the sixth reflecting surface 124c is totally reflected at a right angle by the sixth reflecting surface 124c, is guided along the Y axis to the fourth exit surface 124a, and reaches the reflecting surface of the fourth focusing optical unit 214.

[0129] The light that reaches the reflecting surface of the fourth focusing optical unit 214 is totally reflected by the reflecting surface of the fourth focusing optical unit 214 forward in the Z-axis direction and downward, where it is focused, and propagates within the fourth light distribution unit 224. In the fourth light distribution section 224, the light of the light beam L4 from the front surface of the fourth focusing optical section 214 is totally reflected by the fourth cutoff line forming surface 224a, and the light of the light beam L4 on which a cutoff line is formed is guided to the third projection lens 233 via the second area section 224B. The light beam L4 that has reached the third projection lens 233 and has a cutoff line formed therein is converged by the third projection lens 233 and emitted forward as low beam irradiation light.

[0130] The light guided from the fifth bonding surface 115 of the incident section 110 to the fifth light-guiding section 125 travels straight along the Y-axis to the seventh reflecting surface 125b, as shown as light beam L5 in Figures 10 to 12, and the light that reaches the seventh reflecting surface 125b is totally reflected by the seventh reflecting surface 125b at a right angle to the other end side in the X-axis direction. The light that is totally reflected at a right angle by the seventh reflecting surface 125b and reaches the eighth reflecting surface 125c is totally reflected at a right angle by the eighth reflecting surface 125c, is guided along the Y axis to the fifth exit surface 125a, and reaches the reflecting surface of the fifth focusing optical unit 215.

[0131] A portion of the light that reaches the reflecting surface of the fifth focusing optical unit 215 is totally reflected by the reflecting surface of the fifth focusing optical unit 215 and focused forward in the Z-axis direction and downward toward the center, and then propagates within the fifth light distribution unit 225. In the fifth light distribution unit 225, a portion of the light of the light beam L5 from the front surface of the fifth light collecting optical unit 215 is totally reflected by the fifth cutoff line forming surface 225a. The light of the light beam L5, which has been reflected by the fifth cutoff line forming surface 225a and has a cutoff line formed thereon, is guided to the third projection lens 233 via the second region 225B.

[0132] In addition, the remaining light that reaches the reflecting surface of the fifth focusing optical unit 215 is totally reflected by the reflecting surface of the fifth focusing optical unit 215 and focused forward in the Z-axis direction and downward toward the center, and then propagates within the fourth light distribution unit 224. In the fourth light distribution unit 224, the remaining light of the light beam L5 from the front surface of the fifth light collecting optical unit 215 is reflected by the fourth cutoff line forming surface 224a. The light of the light beam L5, which has been reflected by the fourth cutoff line forming surface 224a and has a cutoff line formed thereon, is guided to the third projection lens 233 via the second region 224B. The light of the light beam L5, which has reached the third projection lens 233 and has a cutoff line formed thereon, is guided from the fourth light distribution section 224 by the third projection lens 233, where a cutoff line is formed, and is combined with the light of the light beam L4, focused, and emitted forward as low beam illumination light.

[0133] The headlight module according to the first embodiment configured in this manner comprises incident section 110, collective light-guiding section 120, and light distribution forming section 200, wherein collective light-guiding section 120 corresponds to each of the multiple joint surfaces of incident section 110, and has multiple exit surfaces located along one direction in a plane orthogonal to the optical axis of light source 1 and the multiple exit surfaces are located along the other direction orthogonal to each other, each of which guides light from the corresponding joint surface to the corresponding exit surface, and the light distribution forming section has at least one projection surface located along the other direction, and the light from the multiple exit surfaces is reflected towards one end in one direction and guided to the projection surface, and light from at least two or more adjacent exit surfaces of the multiple exit surfaces is combined and guided to one of the projection surfaces, thereby enabling the width in the X-axis direction to be narrowed and miniaturization to be achieved, and since light from the multiple exit surfaces is projected onto fewer projection surfaces than the number of the multiple exit surfaces, it is easy to form a light distribution pattern of the light projected from the projection surfaces.

[0134] The headlamp module according to the first embodiment includes a light-source distribution element 100 and a light distribution forming unit 200. The light-source distribution element 100 receives light from a light source 1 and has first to fifth exit surfaces 121a to 125a. The first to fifth exit surfaces 121a to 125a do not overlap in the Z-axis direction (traveling direction) and the X-axis direction (left-right direction), and are arranged in the order of third exit surface 123a, second exit surface 122a, first exit surface 121a, fourth exit surface 124a, and fifth exit surface 125a from one end side to the other end side in the X-axis direction. The light-source distribution element 100 distributes the light incident from the light source 1 through the first to fifth exit surfaces 121a to 125a. a, and the light distribution forming unit 200 has a first projection surface 231a to a third projection surface 233a positioned along the X-axis direction, and light from the first exit surface 121a to the fifth exit surface 125a in the light-source distribution element 100 is totally reflected forward in the Z-axis direction and guided from the first projection surface 231a to the third projection surface 233a, so that the width in the X-axis direction can be narrowed to achieve miniaturization, and furthermore, since the light from the first exit surface 121a to the fifth exit surface 125a is projected from the first projection surface 231a to the third projection surface 233a, it is easy to form a light distribution pattern of the light projected from the first projection surface 231a to the third projection surface 233a.

[0135] In the headlight module according to embodiment 1, the light distribution forming section 200 has a cutoff line forming surface 220a having ridge lines for forming a cutoff line along another direction, and projects a cutoff light distribution formed by reflecting a portion of the light from the collective light-guiding section 120 at the cutoff line forming surface 220a and guiding it to the projection surface, and guiding the other light from the collective light-guiding section 120 directly to the projection surface. This simplifies the structure, reduces the width in the X-axis direction to enable miniaturization, and makes it easy to form a light distribution pattern of the light projected from the projection surface.

[0136] The headlamp module according to the first embodiment includes a light distribution forming unit 200 including a collective light collecting optical unit 210 having a first light collecting optical unit 211 to a fifth light collecting optical unit 215, a collective light distribution unit 220 having a first light distribution unit 221 to a fifth light distribution unit 225, and a projection unit 230 including a first projection lens 231 having a first projection surface 231a to a third projection lens 233 having a third projection surface 233a, and the first light distribution unit 221 to the fifth light distribution unit 225 each have cutoff line forming surfaces 221a to 225a having ridge lines for forming a cutoff line along the X-axis direction, the first light distribution unit 221 guides light of a light flux L1 from the first light collecting optical unit 211 to the first projection lens 231 as light of a light flux L1 on which a cutoff line has been formed, and the second light distribution unit 222 guides light of the second light collecting optical unit 210 to the first projection lens 231 as light of the light flux L1 on which a cutoff line has been formed. The third light distribution unit 223 guides the light of the light beam L2 from the third converging optical unit 213 to the second projection lens 232 as the light of the light beam L2 on which a cutoff line has been formed, the third light distribution unit 223 guides the light of the light beam L3 from the third converging optical unit 213 to the second projection lens 232 as the light of the light beam L3 on which a cutoff line has been formed, the fourth light distribution unit 224 guides the light of the light beam L4 from the fourth converging optical unit 214 to the third projection lens 233 as the light of the light beam L4 on which a cutoff line has been formed, and the fifth light distribution unit 225 guides the light of the light beam L5 from the fifth converging optical unit 215 to the third projection lens 233 as the light of the light beam L5 on which a cutoff line has been formed. This simplifies the structure, reduces the width in the X-axis direction, and enables miniaturization, and makes it easy to form a light distribution pattern of the light projected from the first projection surface 231a to the third projection surface 233a.

[0137] In the headlamp module according to the first embodiment, the light-source distribution element 100 has an incident portion 110 and a collective light-guiding portion 120 having a first light-guiding portion 121 having a first exit surface 121a to a fifth light-guiding portion 125 having a fifth exit surface 125a, and a pair of opposing surfaces of each of the second light-guiding portion 122 and the third light-guiding portion 123 has a pair of reflecting surfaces 122b, 122c, 123b, 123c on one end side in the X-axis direction, which are inclined at 45 degrees with respect to the corresponding joint surfaces 112, 113 of the incident portion 110, and The pair of opposing surfaces has a pair of reflecting surfaces 124b, 124c, 125b, 125c on the other end side in the X-axis direction that are inclined at 45 degrees with respect to the corresponding joint surfaces 114, 115 of incident section 110, and the incident light beam that is incident on incident section 110 from first light-guiding section 121 by fifth light-guiding section 125 is branched and emitted from first exit surface 121a to fifth exit surface 125a, so that the apparent size of the light source in the division direction from first exit surface 121a to fifth exit surface 125a, which is the light-emitting reference surface, i.e., in the Z-axis direction, can be made smaller.

[0138] Therefore, the light utilization efficiency of the light source distribution element 100 is not degraded, and the light source distribution element 100 can be made thinner in the Z-axis direction without reducing the light utilization efficiency by simplifying the structure. As a result, the height of the headlight module from the first projection surface 231a to the third projection surface 233a can be reduced, and the headlight module can be made thinner in the height direction by simplifying the structure without reducing the light utilization efficiency.

[0139] The headlight module according to embodiment 1 is resistant to variations in placement accuracy for the light beams projected from the first projection surface 231a to the third projection surface 233a, and is easy to handle, because the light source distribution element 100 and the light distribution forming unit 200 are integrally formed from a transparent material. Furthermore, by forming them integrally, loss due to Fresnel reflection can be reduced. The headlight module according to the first embodiment may be used as one element of a low-beam automobile headlight device, and a plurality of headlight modules according to the first embodiment may be arranged in parallel in other directions, that is, in the left-right direction of the automobile.

[0140] Embodiment 2 A headlamp module according to a second embodiment will be described with reference to FIG. The headlight module of embodiment 2 is the same as the headlight module of embodiment 1 in that, while the first cutoff line forming surface 221a to the fifth cutoff line forming surface 225a of the headlight module of embodiment 1 are each unique surfaces and the reflective surfaces on the bottom surfaces of the first light distribution section 221 to the fifth light distribution section 225 are each unique surfaces, the second cutoff line forming surface 222a and the third cutoff line forming surface 223a are located on the same plane and the fourth cutoff line forming surface 224a and the fifth cutoff line forming surface 225a are located on the same plane. In FIG. 14, the same reference numerals as those in FIGS. 1 to 13 indicate the same or corresponding parts.

[0141] The following description will focus on the differences from the headlamp module according to the first embodiment. First light distribution section 221 is the same as first light distribution section 221 in the first embodiment. The second cutoff line forming surface 222a in the second light distribution section 222 and the third cutoff line forming surface 223a in the third light distribution section 223 have ridgelines for forming a continuous cutoff line along the X-axis direction, and are common cutoff line forming surfaces that are continuous along the X-axis direction on the same plane.

[0142] The second cutoff line forming surface 222a, which is a reflective surface on the bottom surface of the first area portion 222A in the second light distribution section 222, and the third cutoff line forming surface 223a, which is a reflective surface on the bottom surface of the first area portion 223A in the third light distribution section 223, are common cutoff line forming surfaces located continuously along the X-axis direction on the same plane parallel to the ZX plane. That is, the second cutoff line forming surface 222a and the third cutoff line forming surface 223a are common reflection surfaces in the first region 222A and the first region 223A, The overall shape is rectangular, with no physical boundary line in the X-axis direction.

[0143] The light of the light beam L2 from the front surface of the second focusing optical unit 212 is reflected by the common reflecting surface of the second cutoff line forming surface 222a and the third cutoff line forming surface 223a, and the light of the light beam L2 with a cutoff line formed thereon is guided to the second projection lens 232 via the second area unit 222B. In addition, the light of the light beam L3 from the front surface of the third focusing optical unit 213 is reflected by the common reflecting surface of the second cutoff line forming surface 222a and the third cutoff line forming surface 223a, and the light of the light beam L3 on which a cutoff line is formed is guided to the second projection lens 232 via the second area unit 223B.

[0144] By changing the shape of the ridge line on the common cutoff line forming surface that becomes the second cutoff line forming surface 222a and the third cutoff line forming surface 223a, a light distribution pattern having a desired cutoff line shape can be obtained from the second projection lens 232.

[0145] The fourth cutoff line forming surface 224a in the fourth light distribution section 224 and the fifth cutoff line forming surface 225a in the fifth light distribution section 225 have ridgelines for forming a continuous cutoff line along the X-axis direction, and are common cutoff line forming surfaces that are continuous along the X-axis direction on the same plane.

[0146] The fourth cutoff line forming surface 224a, which is a reflective surface on the bottom surface of the first area portion 224A in the fourth light distribution section 224, and the fifth cutoff line forming surface 225a, which is a reflective surface on the bottom surface of the first area portion 225A in the fifth light distribution section 225, are common reflective surfaces located continuously along the X-axis direction on the same plane parallel to the ZX plane. That is, the fourth cutoff line forming surface 224a and the fifth cutoff line forming surface 225a are common reflective surfaces in the first area portion 224A and the first area portion 225A, and have an overall rectangular shape with no physical boundary line in the X-axis direction.

[0147] The light of the light beam L4 from the front surface of the fourth focusing optical unit 214 is reflected by the common reflecting surface of the fourth cutoff line forming surface 224a and the fifth cutoff line forming surface 225a, and the light of the light beam L4 with a cutoff line formed thereon is guided to the third projection lens 233 via the second area unit 224B. In addition, the light of the light beam L5 from the front surface of the fifth focusing optical unit 215 is reflected by the common reflecting surface of the fourth cutoff line forming surface 224a and the fifth cutoff line forming surface 225a, and the light of the light beam L5 on which a cutoff line is formed is guided to the third projection lens 233 via the second area unit 225B.

[0148] By changing the shape of the ridge line on the common cutoff line forming surface for the fourth cutoff line forming surface 224a and the fifth cutoff line forming surface 225a, a light distribution pattern having a desired cutoff line shape can be obtained from the third projection lens 233.

[0149] The headlight module according to the second embodiment configured in this manner not only achieves the same effects as the headlight module according to the first embodiment, but also has the advantage that the second cutoff line forming surface 222a and the third cutoff line forming surface 223a are common cutoff line forming surfaces positioned consecutively along the X-axis direction on the same plane, and the fourth cutoff line forming surface 224a and the fifth cutoff line forming surface 225a are common cutoff line forming surfaces positioned consecutively along the X-axis direction on the same plane, thereby simplifying the structure of the collective light distribution section 220 and making it easier to form a light distribution pattern of the projected light from the projection surfaces by the first projection surface 231a to the third projection surface 233a.

[0150] Embodiment 3 A headlamp module according to a third embodiment will be described with reference to FIG. The headlight module of embodiment 3 is the same as the headlight module of embodiment 1 in that the first cutoff line forming surface 221a to the fifth cutoff line forming surface 225a are each unique surfaces, and the reflective surfaces on the bottom surfaces of the first light distribution section 221 to the fifth light distribution section 225 are each unique surfaces, but in other respects the first cutoff line forming surface 221a to the fifth cutoff line forming surface 225a are located on the same plane. In FIG. 15, the same reference numerals as those in FIGS. 1 to 13 indicate the same or corresponding parts.

[0151] The following description will focus on the differences from the headlamp module according to the first embodiment. The first cutoff line forming surface 221a in the first light distribution section 221 to the fifth cutoff line forming surface 225a in the fifth light distribution section 225 have ridgelines for forming continuous cutoff lines along the X-axis direction, and are common cutoff line forming surfaces that are continuous along the X-axis direction on the same plane.

[0152] The first cutoff line forming surface 221a, which is a reflective surface on the bottom surface of the first area portion 221A in the first light distribution section 221, to the fifth cutoff line forming surface 225a, which is a reflective surface on the bottom surface of the first area portion 225A in the fifth light distribution section 225, are common cutoff line forming surfaces located continuously along the X-axis direction on the same plane parallel to the ZX plane. That is, the first cutoff line forming surface 221a to the fifth cutoff line forming surface 225a are common reflecting surfaces in the first region 220A, and have a rectangular overall shape with no physical boundary line in the X-axis direction.

[0153] The light beam L1 from the front surface of the first focusing optical unit 211 is reflected by a common cutoff line forming surface, and the light beam L1 with a cutoff line formed thereon is guided to the first projection lens 231 via the second area unit 221B. The light beam L2 from the front surface of the second focusing optical unit 212 is reflected by a common cutoff line forming surface, and the light beam L2 with a cutoff line formed thereon is guided to the second projection lens 232 via the second area unit 222B.

[0154] The light beam L3 from the front surface of the third focusing optical unit 213 is reflected by a common cutoff line forming surface, and the light beam L3 with a cutoff line formed thereon is guided to the second projection lens 232 via the second area unit 223B. The light beam L4 from the front surface of the fourth focusing optical unit 214 is reflected by a common cutoff line forming surface, and the light beam L4 with a cutoff line formed thereon is guided to the third projection lens 233 via the second area unit 224B.

[0155] The light beam L5 from the front surface of the fifth focusing optical unit 215 is reflected by a common cutoff line forming surface, and the light beam L5 with a cutoff line formed thereon is guided to the third projection lens 233 via the second area unit 225B. By changing the shape of the ridge line on the common cutoff line forming surface, which is the first cutoff line forming surface 221a to the fifth cutoff line forming surface 225a, a light distribution pattern having a desired cutoff line shape can be obtained from the projection lenses consisting of the first projection lens 231 to the third projection lens 233.

[0156] The headlight module of embodiment 3 configured in this manner not only achieves the same effects as the headlight module of embodiment 1, but also has the first cutoff line forming surface 221a to the fifth cutoff line forming surface 225a as common cutoff line forming surfaces positioned continuously along the X-axis direction on the same plane, thereby simplifying the structure of the collective light distribution section 220 and making it easier to form a light distribution pattern of the projected light from the projection surfaces by the first projection surface 231a to the third projection surface 233a.

[0157] In all the embodiments, the case where there are five light guiding sections and focusing optical sections and three projection lenses has been described, but this is not limited to this, and the number of light guiding sections, focusing optical sections and projection lenses can be set arbitrarily as long as the configuration is such that light is combined from at least two adjacent focusing optical sections and directed to one projection lens.

[0158] Furthermore, the embodiments may be freely combined, or any of the components in each embodiment may be modified, or any of the components in each embodiment may be omitted. [Industrial Applicability]

[0159] The light source distribution element for a headlamp device and the headlamp module according to the present disclosure are suitable for use in headlamp devices for automobiles and motorcycles, particularly in low-beam headlights. [Explanation of symbols]

[0160] 1 light source, 100 light source distribution element for headlamp device, 110 incident portion, 111 first bonding surface, 112 second bonding surface, 113 third bonding surface, 114 fourth bonding surface, 115 fifth bonding surface, 120 collective light guiding portion, 121 first light guiding portion, 122 second light guiding portion, 123 third light guiding portion, 124 fourth light guiding portion, 125 fifth light guiding portion, 121a first exit surface, 122a second exit surface, 123a third exit surface, 124a fourth exit surface, 125a fifth exit surface, 122b first reflecting surface, 122c second reflecting surface, 123b third reflecting surface, 123c fourth reflecting surface, 124b fifth reflecting surface, 124c Sixth reflecting surface, 125b Seventh reflecting surface, 125c Eighth reflecting surface, 200 Light distribution forming portion, 210 Collecting and concentrating optical portion, 211 First concentrating optical portion, 212 Second concentrating optical portion, 213 Third concentrating optical portion, 214 Fourth concentrating optical portion, 215 Fifth concentrating optical portion, 220 Collecting and concentrating optical portion, 220A First region, 220B Second region, 220a Cutoff line forming surface, 221 First light distribution portion, 221a First cutoff line forming surface, 222 Second light distribution portion, 222a Second cutoff line forming surface, 223 Third light distribution portion, 223a Third cutoff line forming surface, 224 Fourth light distribution portion, 224a Fourth cutoff line forming surface, 225 Fifth light distribution portion, 225a Fifth cutoff line forming surface, 230 projection unit, 231 first projection lens, 232 second projection lens, 233 third projection lens, 231a first projection surface, 232a second projection surface, 233a third projection surface, L1 to L5 first light beam to third light beam.

Claims

1. an incident portion to which light from a light source is incident and which has a plurality of bonding surfaces positioned along one direction in a plane perpendicular to an optical axis of the light source; a collective light-guiding section including a plurality of exit surfaces corresponding to the plurality of bonding surfaces of the incident section and positioned along one direction and another direction orthogonal to the optical axis of the light source in a plane orthogonal to the optical axis of the light source, each of which guides light from the corresponding bonding surface to the corresponding exit surface; a light distribution forming unit having at least one projection surface positioned along the other direction, which reflects light from the plurality of exit surfaces toward one end side in the one direction and guides the light to the projection surface, the light distribution forming unit combines and guides light from at least two or more adjacent exit surfaces of the plurality of exit surfaces to one of the projection surfaces, Headlight module.

2. the light distribution forming portion has a cutoff line forming surface having a ridge line for forming a cutoff line along the other direction, a cutoff light distribution formed by reflecting a portion of the light from the collective light-guiding unit onto the cutoff line forming surface and guiding the remaining light from the collective light-guiding unit onto the projection surface is projected; The headlamp module according to claim 1 .

3. the collective light-guiding section has a pair of opposing surfaces that face one direction and another direction that are perpendicular to the plane perpendicular to the optical axis of the light source, and has a rectangular cross section parallel to the plane perpendicular to the optical axis of the light source, and each has an exit surface corresponding to each of the plurality of bonding surfaces of the incident section, and is composed of a plurality of light-guiding sections that guide light from the corresponding bonding surface to the corresponding exit surface, Among the plurality of light guiding sections, each of the pair of opposing surfaces of a light guiding section whose exit surface is located on one end side in the other direction relative to the light source has a reflection surface on one end side that is inclined with respect to the optical axis of the light source, Among the plurality of light guiding sections, each of the pair of opposing surfaces of a light guiding section whose exit surface is located on the other end side in the other direction relative to the light source has a reflection surface on the other end side that is inclined with respect to the optical axis of the light source.

3. The headlamp module according to claim 1 or 2.

4. the collective light-guiding unit has a first exit surface to a fifth exit surface, and the first exit surface to the fifth exit surface are arranged in another direction perpendicular to the one direction in the order of a third exit surface, a second exit surface, a first exit surface, a fourth exit surface, and a fifth exit surface, from one end side to the other end side, and guides light incident from the light source from the first exit surface to the fifth exit surface, the light distribution forming unit has first to third projection surfaces positioned along the other direction, and is arranged in the order of the second projection surface, the first projection surface, and the third projection surface from one end side to the other end side in the other direction, and reflects light from the first to fifth exit surfaces of the collective light guiding unit toward one end side in the one direction, and guides the light from the first projection surface to the third projection surface; The light distribution forming unit is a first light-collecting optical unit that reflects and collects light from the first light exit surface toward one end side in the one direction; a second light-collecting optical unit that reflects and collects light from the second light exit surface toward one end side in the one direction; a third light-collecting optical unit that reflects and collects light from the third light exit surface toward one end side in the one direction; a fourth light-collecting optical unit that reflects and collects light from the fourth light exit surface toward one end side in the one direction; a fifth light-collecting optical unit that reflects and collects light from the fifth light exit surface toward one end side in the one direction; a first light distribution unit that guides the light flux reflected and concentrated by the first converging optical unit to the first projection surface; a second light distribution unit that guides the light flux reflected and concentrated by the second converging optical unit to the second projection surface; a third light distribution unit that guides the light flux reflected and concentrated by the third converging optical unit to the second projection surface; a fourth light distribution unit that guides the light flux reflected and concentrated by the fourth converging optical unit to the third projection surface; a fifth light distribution unit that guides the light flux reflected and concentrated by the fifth converging optical unit to the third projection surface; a first projection lens having a first projection surface and projecting, from the first projection surface, the light guided as a luminous flux by the first light distribution unit; a second projection lens having a second projection surface and projecting, from the second projection surface, the light guided as a luminous flux by the second light distribution section and the third light distribution section; a third projection lens having a third projection surface and projecting the light guided as a luminous flux by the fourth light distribution section and the fifth light distribution section from the third projection surface; The headlamp module according to claim 1 .

5. the first light distribution unit has a first cutoff line forming surface having a ridge line for forming a cutoff line along the other direction, and projects a cutoff light distribution formed by reflecting a portion of the light from the first converging optical unit on the first cutoff line forming surface and guiding the portion of the light from the first converging optical unit directly to the first projection surface, the second light distribution unit has a second cutoff line forming surface having a ridge line for forming a cutoff line along the other direction, and projects a cutoff light distribution formed by reflecting a portion of the light from the second concentrating optical unit on the second cutoff line forming surface and guiding the portion of the light from the second concentrating optical unit directly to the second projection surface, the third light distribution unit has a third cutoff line forming surface having a ridge line for forming a cutoff line along the other direction, and projects a cutoff light distribution formed by reflecting a portion of the light from the third concentrating optical unit on the third cutoff line forming surface and guiding the portion of the light from the third concentrating optical unit to the second projection surface, and guiding the remaining light from the third concentrating optical unit directly to the second projection surface; the fourth light distribution unit has a fourth cutoff line forming surface having a ridge line for forming a cutoff line along the other direction, and projects a cutoff light distribution formed by reflecting a portion of the light from the fourth concentrating optical unit on the fourth cutoff line forming surface and guiding the portion of the light from the fourth concentrating optical unit to the third projection surface, and guiding the remaining light from the fourth concentrating optical unit directly to the third projection surface; the fifth light distribution unit has a fifth cutoff line forming surface having a ridge line for forming a cutoff line along the other direction, and projects a cutoff light distribution formed by reflecting a portion of the light from the fifth concentrating optical unit on the fifth cutoff line forming surface and guiding the portion of the light from the fifth concentrating optical unit to the third projection surface, and guiding the remaining light from the fifth concentrating optical unit directly to the third projection surface.

5. The headlamp module according to claim 4.

6. the first cutoff line forming surface to the fifth cutoff line forming surface are surfaces each having unique characteristics, 6. The headlamp module according to claim 5.

7. the second cutoff line forming surface and the third cutoff line forming surface are located on the same plane, the fourth cutoff line forming surface and the fifth cutoff line forming surface are located on the same plane.

6. The headlamp module according to claim 5.

8. the first cutoff line forming surface to the fifth cutoff line forming surface are located on the same plane, 6. The headlamp module according to claim 5.

9. the collective light guiding section is composed of first to fifth light guiding sections, the incident portion receives light from a light source, is divided along the one direction, and has a first bonding surface at a central portion, a second bonding surface and a third bonding surface disposed in this order from the central portion toward one end side in the one direction, and a fourth bonding surface and a fifth bonding surface disposed in this order from the central portion toward the other end side in the one direction, the first light guiding unit has the first exit surface and a pair of opposing surfaces that are parallel to the optical axis of the light source and face in the other direction, and guides light from a first joint surface of the incident unit to the first exit surface; the second light guiding unit has the second emission surface and a pair of opposing surfaces facing in the other direction, a first reflecting surface on an opposing surface located on a central side of the pair of opposing surfaces, and a second reflecting surface on an opposing surface located on one end side of the pair of opposing surfaces, the first reflecting surface and the second reflecting surface being inclined toward the one end side in the other direction with respect to the optical axis of the light source, and the second light guiding unit reflects light from the second joint surface of the incident unit to the second reflecting surface by the first reflecting surface, and the second reflecting surface reflects light to the second emission surface by The third light guiding unit has the third emission surface and a pair of opposing surfaces facing in the other direction, a third reflecting surface on an opposing surface located on a center side of the pair of opposing surfaces, and a fourth reflecting surface on an opposing surface located on one end side of the pair of opposing surfaces, the third reflecting surface and the fourth reflecting surface being inclined toward one end side in the other direction with respect to the optical axis of the light source, the third reflecting surface of the third light guiding unit being continuous with the first reflecting surface on one end side in the one direction, a fourth reflecting surface of the third light guiding portion is located at a position away from the position of the second reflecting surface of the second light guiding portion by a length of the third exit surface in the other direction toward one end side of the other direction, and the third reflecting surface of the third light guiding portion reflects light from a third joint surface of the incident portion to the fourth reflecting surface, and the fourth reflecting surface reflects light to the third exit surface, the fourth light guiding unit has the fourth emission surface and a pair of opposing surfaces facing in the other direction, a fifth reflecting surface on an opposing surface located on a central side of the pair of opposing surfaces, and a sixth reflecting surface on an opposing surface located on the other end side of the pair of opposing surfaces, the fifth reflecting surface and the sixth reflecting surface being inclined toward the other end side in the other direction with respect to the optical axis of the light source, the fourth light guiding unit reflects light from a fourth joint surface of the incident unit to the sixth reflecting surface, and the sixth reflecting surface reflects light to the fourth emission surface, The fifth light guiding unit has the fifth emission surface and a pair of opposing surfaces facing in the other direction, a seventh reflecting surface on an opposing surface located on a central side of the pair of opposing surfaces, and an eighth reflecting surface on an opposing surface located on the other end side of the pair of opposing surfaces, the seventh reflecting surface and the eighth reflecting surface being inclined toward the other end side in the other direction with respect to the optical axis of the light source, the seventh reflecting surface of the fifth light guiding unit being continuous with the fifth reflecting surface on the other end side in the one direction, the fifth light guiding section is formed integrally with the fifth reflecting surface from the fifth joint surface of the fourth light guiding section to the sixth reflecting surface, the eighth reflecting surface of the fifth light guiding section is located at a distance from the sixth reflecting surface of the fourth light guiding section to the other end side in the other direction by a length of the fifth exit surface in the other direction of the fifth light guiding section, and the fifth light guiding section reflects light from the fifth joint surface of the incident section to the eighth reflecting surface, and the eighth reflecting surface reflects light to the fifth exit surface, A headlamp module according to any one of claims 5 to 8.

10. The headlamp module according to claim 9 , wherein the incident portion condenses incident light and guides the light in parallel from the first joint surface to the fifth joint surface.

11. The headlamp module according to any one of claims 1 to 8, wherein the incident portion, the collective light guiding portion, and the light distribution forming portion are integrally formed from a transparent material.

12. A headlight module as described in Claim 3, wherein the incident portion, the collective light-guiding portion, and the light distribution forming portion are integrally formed from a transparent material.

13. A headlight module as described in Claim 9, wherein the incident portion, the collective light-guiding portion, and the light distribution forming portion are integrally formed from a transparent material.

14. A headlight module as described in Claim 10, wherein the incident portion, the collective light-guiding portion, and the light distribution forming portion are integrally formed from a transparent material.

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