Vehicle lighting fixtures

Abstract

To use a lighting tool internal structure to improve rigidity of a lamp body.SOLUTION: A vehicle lighting tool (1) includes: a container-shaped lamp body (2) with a front surface being opened; a front surface cover (4) assembled to the front surface opening of the lamp body (2) and defining a lighting chamber (S) on an inner side; and a lighting tool internal structure (50) provided inside the lighting chamber (S). On a back wall (6) of the lamp body (2), a plurality of beams (61 to 67) configured by a part of the back wall (6) extend in a truss manner, each of the beams having a substantially arched shape in a cross-section. At least one of the beams (61 to 67) supports the lighting tool internal structure (50). The beam supporting the lighting tool internal structure reinforces the beam by having rigidity of the lighting tool internal structure serving as a part of the rigidity of the beam.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to a vehicle lamp having a lamp body and a front cover. [Background technology]

[0002] Conventionally, structures arranged inside the lamp chamber (structures inside the lamp fixture), such as a control unit, have been arranged in the empty space of the lamp body. For example, in Patent Document 1, the control unit for swivel drive is fixed in the empty space of the box-shaped lamp body. Furthermore, in recent years, there has been a movement toward lighter lamp bodies from the perspective of carbon neutrality. However, simply reducing the thickness of the lamp body may result in a decrease in the rigidity of the body, so maintaining the rigidity of the lamp body is an issue. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2016-110853 Summary of the Invention [Problem to be solved by the invention]

[0004] Providing reinforcing ribs is one way to improve the rigidity of the lamp body, but providing reinforcing ribs increases the weight of the lamp body.

[0005] The present invention has been proposed to solve the above-mentioned problems, and aims to utilize the internal structure of the lamp that was disposed in the empty space to improve the rigidity of the lamp body. [Means for solving the problem]

[0006] To solve the above problems, a first aspect of the present invention provides a vehicle lamp comprising a container-shaped lamp body with an open front, a front cover attached to the front opening of the lamp body to define a lamp chamber therein, and an internal lamp structure disposed within the lamp chamber, wherein a plurality of beams, each of which is formed by a portion of the container surface and has a generally arc-shaped cross section, extend in a truss-like manner from the container surface of the lamp body, and the internal lamp structure is supported by at least one of the beams. According to this aspect, the internal lamp structure is supported by at least one of the beams of the truss structure formed in the lamp body, and the rigidity of the internal lamp structure serves as part of the rigidity of the beam, reinforcing the beam and improving the strength of the truss structure. The increased rigidity of the truss structure allows the lamp body to be made thinner and lighter.

[0007] In the vehicle lamp of the second aspect, it is also preferable that the structure within the lamp is disposed in a beam that is subjected to a compressive axial force among the beams. According to this aspect, the resistance to deformation and buckling of the compression members of the truss structure can be increased, thereby further increasing the rigidity of the truss structure.

[0008] In the vehicle lamp of the third aspect, in the first or second aspect, it is also preferable that the internal structure of the lamp is long and that the longitudinal direction of the internal structure of the lamp is aligned with the axial direction of the beam. According to this aspect, the internal structure of the lamp functions like a pillar on the beam that supports the internal structure of the lamp, thereby further increasing the rigidity of the truss structure.

[0009] In the vehicle lamp of the fourth aspect, in any one of the first to third aspects, it is also preferable that at least one undulation is formed in the longitudinal direction of the lamp internal structure on the container surface near the beam supporting the lamp internal structure. According to this aspect, stress transmitted from the container surface near the beam supporting the lamp internal structure is dispersed by the curvature of the undulation. As a result, the surface strength of the beam supporting the lamp internal structure can be increased, and the rigidity of the truss structure can be further increased.

[0010] In the vehicle lamp of the fifth aspect, in any one of the first to fourth aspects, it is also preferable that the lamp internal structure is fixed so as to be coupled to another container surface other than the container surface having the beam supporting the lamp internal structure. According to this aspect, the rigidity of the beam supporting the lamp internal structure can rely on the rigidity of another container surface via the lamp internal structure, thereby further increasing the rigidity of the truss structure. [Effects of the Invention]

[0011] According to the present invention, the internal structure of the lamp that was disposed in the empty space can be utilized to improve the rigidity of the lamp body, thereby making it possible to reduce the weight of the lamp body. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a schematic front view of a vehicle lamp 1 according to an embodiment of the present invention. [Figure 2] FIG. 2 is a schematic front view of the lamp body 2 of the lighting fixture 1. [Figure 3] 3A and 3B are end views of the lamp body 2 in FIG. 2, including (A) an end view along line AA, (B) an end view along line BB, (C) an end view along line CC, (D) an end view along line DD, (E) an end view along line EE, (F) an end view along line FF, and (G) an end view along line GG. [Figure 4] 3 is a diagram illustrating a truss structure formed in the lamp body 2 of FIG. 2. FIG. [Figure 5] FIG. 3 is an enlarged view of part H in FIG. 2. [Figure 6] 6 is a diagram showing an LDM 50 disposed at part H in FIG. 5. [Figure 7] FIG. 7 is a plan view of FIG. 6. [Figure 8] FIG. 1 is a diagram showing a vehicle lamp 110 according to a first modified example of the embodiment. [Figure 9] FIG. 10 is a diagram showing a vehicle lamp 120 according to a second modified example of the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0013] Specific embodiments of the present invention will be described below with reference to the drawings. The embodiments are illustrative and do not limit the invention, and all features and combinations thereof described in the embodiments are not necessarily essential to the invention. In addition, in the following description of the embodiments and modifications, the same components are designated by the same reference numerals, and duplicated descriptions will be omitted as appropriate.

[0014] (vehicle lighting fixtures) FIG. 1 is a schematic front view of a vehicle lamp 1 according to a preferred embodiment of the present invention. The vehicle lamp 1 is a headlamp mounted on the left and right corners of the front of a vehicle. As shown in FIG. 1, the vehicle lamp 1 comprises a container-shaped lamp body 2 that is open at the front, and a front cover 4 that is attached to a front opening 2' of the lamp body 2 (see FIG. 2, described later). The front cover 4 is made of a translucent resin such as polycarbonate or glass, and by attaching the front cover 4 to the front opening 2' of the lamp body 2, a lamp chamber S is defined inside.

[0015] A high beam lamp unit Hi and a low beam lamp unit Lo are housed within the defined lamp chamber S. The high beam lamp unit Hi and the low beam lamp unit Lo are optical units configured to irradiate light emitted from a light source ahead of the vehicle to form a high beam light distribution and a low beam light distribution, respectively. Each lamp unit (Hi, Lo) may be of any type, and may be of a conventionally known configuration, such as a reflector type or projector type.

[0016] (Overall shape of the lamp body) The shape of the lamp body 2 will be described in detail below. FIG.

[0017] The lamp body 2 is formed by injection molding using a hard synthetic resin material. A seal groove 3 is provided around the periphery of the front opening 2' of the lamp body 2 to engage with a seal leg provided around the periphery of the front cover 4. On the outer surface of the periphery of the front opening 2' of the lamp body 2, a vehicle body mounting portion 5 for mounting to the vehicle body is provided so as to protrude in accordance with the shape of the mounting portion on the vehicle body side. The vehicle body mounting portions 5 are provided in a total of five locations on the outer surface of the lamp body 2: three on the top and two on the left.

[0018] The lamp body 2 has, as its constituent surfaces, a rear wall 6, a ceiling surface 7, a bottom surface 8, and left and right side surfaces 9, 9, and the rear wall 6 bulges backward and is continuously connected (curvedly) to the adjacent ceiling surface 7, bottom surface 8, and side surfaces 9, 9 via ridges.

[0019] The bottom surface 8 extends forward from the lower edge of the rear wall 6 and connects to the seal groove 3 provided on the edge of the front opening 2' of the lamp body 2. The side surfaces 9, 9 extend laterally and slightly forward from the left and right edges of the rear wall 6 and connect to the seal groove 3. The ceiling surface 7 extends only a small amount, and extends from the edge of the seal groove 3 while curving gently downward toward the rear side to connect to the rear wall 6 and is formed substantially integrally with the rear wall 6.

[0020] For this reason, the rear wall 6, ceiling surface 7, bottom surface 8, and side surfaces 9, 9 are not primarily flat but are composed of curved surfaces with a large radius of curvature, and the lamp body 2 as a whole is formed in the shape of a container with the rear wall 6 as the bottom, and each of the rear wall 6, ceiling surface 7, bottom surface 8, and side surfaces 9, 9 form a container surface in which the curved surfaces of each are smoothly continuous with each other.

[0021] The lamp body 2 is formed with a first unit mounting hole 31, a second unit mounting hole 32, and a third unit mounting hole 33. The first unit mounting hole 31 is a hole for mounting a lamp unit Hi for high beams, and is formed in the upper left of the rear wall 6. The second unit mounting hole 32 is a hole for mounting a back cover (not shown), and is formed in the upper right of the rear wall 6. The third unit mounting hole 33 is a hole for mounting a light driver module 50 (described later; hereinafter referred to as LDM) that controls the lighting of the lamp units (Hi, Lo), and is formed in the lower center of the rear wall 6.

[0022] The lamp body 2 also has a first aiming member mounting hole 41, a second aiming member mounting hole 42, and a third aiming member mounting hole 43 formed around the third unit mounting hole 33. A conventionally known aiming member (not shown) is mounted in each of the aiming member mounting holes 41, 42, and 43. The first aiming member mounting hole 41 is provided in the left lower edge of the rear wall 6 so as to be positioned between the third unit mounting hole 33 and the first unit mounting hole 31. The second aiming member mounting hole 42 is provided in the right lower edge of the rear wall 6 so as to be offset in the opposite direction from the first aiming member mounting hole 41 by approximately the same distance as the distance from the third unit mounting hole 33 to the first aiming member mounting hole 41. The third aiming member mounting hole 43 is formed in the right upper end of the rear wall 6 so as to be positioned approximately vertically above the second aiming member mounting hole 42.

[0023] (Lamp body beam structure) On the rear wall 6 of the lamp body 2, a first beam 61, a second beam 62, a third beam 63, a fourth beam 64, a fifth beam 65, a sixth beam 66, and a seventh beam 67, which constitute a part of the rear wall 6, extend over substantially the entire rear wall 6. The first beam 61 extends from the first aiming member mounting hole 41 and the first unit mounting hole 31 as end points, connecting them, and is formed as a beam tilting to the left. The second beam 62 extends from the first aiming member mounting hole 41 generally upward to the upper end of the rear wall 6, and is formed as a beam extending substantially vertically. The third beam 63 extends from the first aiming member mounting hole 41 to the upper central end of the rear wall 6 as end points, connecting them, and is formed as a beam tilting to the right. The fourth beam 64 extends from the upper central end of the rear wall 6 to the second aiming member mounting hole 42 as its end points, and is formed as a beam tilting to the left. The fifth beam 65 extends from the first aiming member mounting hole 41 to the second aiming member mounting hole 42 as its end points, and is formed as a beam extending substantially horizontally. The sixth beam 66 extends from the second aiming member mounting hole 42 to the third aiming member mounting hole 43 as its end points, and is formed as a beam extending substantially vertically. The seventh beam 67 extends from the second aiming member mounting hole 42 to the second unit mounting hole 32 as its end points, and is formed as a beam tilting to the right.

[0024] FIG. 3 is an end view of each beam 61-67 along the cutting line shown in FIG. 2. FIG. 3(A) is an end view along line AA, showing the cross-sectional shape of the first beam 61. FIG. 3(B) is an end view along line BB, showing the cross-sectional shape of the second beam 62. FIG. 3(C) is an end view along line CC, showing the cross-sectional shape of the third beam 63 at the top and the cross-sectional shape of the left end of the fifth beam 65 at the bottom. FIG. 3(D) is an end view along line DD, showing the cross-sectional shape of the fourth beam 64 at the top and the cross-sectional shape of the right end of the fifth beam 65 at the bottom. FIG. 3(E) is an end view along line EE, showing the cross-sectional shape of the sixth beam 66. FIG. 3(F) is an end view along line FF, showing the cross-sectional shape of the seventh beam 67. FIG. 3(G) is an end view along line GG, showing the cross-sectional shape of the fourth beam 64 at the top and the cross-sectional shape of the central part of the fifth beam 65 at the bottom. A third unit mounting hole 33 is formed in the center of the fifth beam 65. In this way, each of the beams 61 to 67 is configured so that the cross section perpendicular to its extension direction is substantially arc-shaped. The protruding direction of the curved surface of each of the beams 61 to 67 may be formed either toward the lamp chamber S (forward) or outward from the lamp chamber S (rearward). In this embodiment, each of the beams 61 to 67 is formed as a beam that curves toward the lamp chamber S (forward).

[0025] 4 is a front view of the lamp body 2, with the truss structure formed in the lamp body 2 indicated in light ink. As mentioned above, the seal groove 3 in the ceiling surface 7 extends like the upper chord of a truss, because the ceiling surface 7 is configured to be substantially integral with the rear wall 6. In the lamp body 2, the truss structure shown in FIG. 4 is formed by connecting the force application points of each beam 61-67 with the seal groove 3 in the ceiling surface 7.

[0026] Therefore, the lamp body 2 of this embodiment has a structure with higher rigidity than a lamp body that does not have such a truss structure.

[0027] (Use of the structure inside the lamp) The higher the rigidity of the truss structure, the thinner the lamp body 2 can be made than before, and the lighter it can be. The structure for achieving this will be described in detail with reference to Figs.

[0028] Fig. 5 is an enlarged view of part H in Fig. 2, Fig. 6 is a view showing the LDM 50 disposed at part H, and Fig. 7 is a plan view of Fig. 6. As shown in Figs. 3(C), 3(D), and 3(G), the fifth beam 65 is configured with a curved surface that is convex toward the lamp chamber S (forward), and as also shown in Fig. 5, a third unit mounting hole 33 is formed in the center of the fifth beam 65. The LDM 50 is fixed to the third unit mounting hole 33, as shown in Fig. 6.

[0029] The LDM (light driver module) 50 is one of the structures within the lamp. In this specification, the term "structure within the lamp" refers to a structure that is placed within the lamp chamber S, and refers to a part, member, or unit that has a predetermined size and strength and that must be placed within the lamp chamber S, such as a lamp unit lighting control unit like the LDM 50, or a lamp unit swivel drive control unit or leveling drive control unit.

[0030] The LDM 50 has a lighting control circuit and an ECU (Electronic Control Unit) on a circuit board (not shown), and a metal case 52 that surrounds the circuit board. The metal case 52 has a rectangular parallelepiped shape, and when fixed, the bottom surface extends slightly beyond the top surface and is open at the front. The back side of the metal case 52 is a connector insertion port 54 (see Figure 7). The connector insertion port 54 has a shape on its periphery that corresponds to the uneven shape formed in the third unit mounting hole 33, and fits into the third unit mounting hole 33. The LDM 50 is supported by the fifth beam 65 by fitting the connector insertion port 54 into the third unit mounting hole 33.

[0031] Furthermore, the left and right side surfaces of the metal case 52 are provided with fixing portions 53 formed integrally with the metal case 52 near the front end of the top surface of the case. The fixing portions 53 are provided with a first pressing plate 531 formed in a stepped shape by bending plates extending horizontally from the left and right side surfaces and offsetting them upward, and a second pressing plate 532 formed by bending the front of the first pressing plate 531 vertically downward, and at least the second pressing plate 532 is formed with a screw insertion hole (not shown).

[0032] Meanwhile, a pair of holding arms 81, 82 for holding the LDM 50 are formed on the left and right sides of the third unit mounting hole 33. The holding arms 81, 82 are formed to be separated by the left-right length of the LDM 50 and are formed so that they are equidistant from the center of the third unit mounting hole 33. The holding arms 81, 82 extend forward in a columnar shape from the rear wall 6 and have their lower ends connected to the bottom surface 8, forming them integrally with the bottom surface 8. The front surfaces 83 of the holding arms 81, 82 are vertical planes that extend forward to a position coinciding with the second presser plate 532 of the LDM 50 and are provided with screw holes 84.

[0033] The LDM50 is cantilevered on the fifth beam 65 by fitting the connector insertion port 54 into the third unit mounting hole 33, and is fixed at three points by screwing the second pressing plate 532 of the fixing part 53 to the front surface 83 of the holding arms 81 and 82, namely the third unit mounting hole 33, the holding arm 81, and the holding arm 82.

[0034] (Action and effect) Conventionally, structures inside a lamp fixture such as an LDM have been arranged in an empty space in the lamp body, for example by forming a box-shaped storage space to support the LDM case, based on the idea that they can be attached anywhere in the lamp body. In contrast, in this embodiment, the LDM 50 (structure inside a lamp fixture) is supported by the fifth beam 65 (truss structure) of the lamp body 2, and the rigidity of the LDM 50 (structure inside a lamp fixture) becomes part of the rigidity of the fifth beam 65, reinforcing the strength of the fifth beam 65.

[0035] In particular, in the truss structure formed in the lamp body 2 of this embodiment, the fifth beam 65 is preferably provided with higher rigidity because it serves as a compression member among the beams 61 to 67. In contrast, in this embodiment, the rigidity of the LDM 50 becomes part of the rigidity of the fifth beam 65, and the rigidity of the compression member of the truss structure can be increased, thereby increasing the resistance of the truss structure formed in the lamp body 2 to deformation and buckling.

[0036] Furthermore, it is preferable that the internal structure of the lamp extends along the axial direction of the beam, since the rigidity of the beam can be relied upon by the rigidity of the internal structure of the lamp. In contrast, in this embodiment, the metal case 52 of the LDM 50 is longest in the left-right direction among the left-right, front-rear, and up-down directions when fixed, and the long sides of the metal case 52 are arranged in the left-right direction, which is the axial direction of the fifth beam 65. Therefore, the LDM 50 functions as a pillar in the fifth beam 65, and the rigidity of the truss structure formed in the lamp body 2 can be further increased.

[0037] Furthermore, by connecting the internal lamp structure to a different container surface from the container surface on which the beams supporting the internal lamp structure are provided, the rigidity of the beams supporting the internal lamp structure can be relied upon through the internal lamp structure from the rigidity of the different container surface, which is preferable. In contrast, in this embodiment, the LDM 50 is fixed at three points, being connected not only to the rear wall 6 (the container surface) on which the fifth beam 65 supporting the LDM 50 is located, but also to the holding arms 81 and 82 formed on the bottom surface 8 (the different container surface) nearby. Therefore, the rigidity of the fifth beam 65 is reinforced by the rigidity of the bottom surface 8. This strengthens the rigidity of the fifth beam 65, further increasing the resistance to deformation and buckling of the truss structure formed in the lamp body 2.

[0038] (Variation) Next, a preferred modification of the above embodiment will be described.

[0039] FIG. 8 shows a vehicle lamp 110 according to a first modified example, and is an enlarged view of the lamp 110 similar to FIG. 5. The fifth beam 65 on which the LDM 50 is disposed is a relatively long beam compared to the other beams 61-64, 66-67. As shown in the embodiment, the lamp internal structure is disposed on such a long beam. Furthermore, as shown in this modified example, it is preferable to form at least one undulation in the longitudinal direction of the lamp internal structure on the case surface near the beam to distribute stress on the beam supporting the lamp internal structure. In this modified example, a bead portion 80 is formed on the bottom surface 8 (case surface) near the fifth beam 65. The bead portion 80 extends from the rear wall 6 to the seal groove 3 at approximately the center below the LDM 50, and the lower end of the bead portion 80 is connected to the bottom surface 8 and is formed integrally with the bottom surface 8. By forming the bead portion 80, a single undulation is formed on the bottom surface 8 (container surface) near the fifth beam 65 in the left-right direction, which is the longitudinal direction of the LDM 50 (lamp internal structure). Therefore, the stress transmitted from the bottom surface 8 to the fifth beam 65 is dispersed by the curvature of the bead portion 80, resulting in a configuration that increases the surface strength of the fifth beam 65. This strengthens the rigidity of the fifth beam 65, further increasing the resistance to deformation and buckling of the truss structure formed in the lamp body 2. The protruding direction of the curvature of the bead portion 80 may be formed either toward the lamp chamber S (upward) or outward from the lamp chamber S (downward). The number of undulations is not limited to one, and multiple undulations may be formed.

[0040] FIG. 9 shows a vehicular lamp 120 according to two modifications, and is a front view of the lamp 120, similar to FIG. 2. In the truss structure formed in the lamp body 2 of the embodiment, the sixth beam 66, among the beams 61 to 67, also serves as a compression member. Therefore, it is preferable that the sixth beam 66 also have high rigidity to prevent deformation and buckling. For this reason, in this modification, an aiming driver module 90 is disposed on the sixth beam 66, which has the third aiming member mounting hole 43. The aiming member driven and controlled by the aiming driver module 90 may have a conventionally known configuration. An aiming screw 102 (or aiming rod) disposed in the third aiming member mounting hole 43 is connected to a lamp bracket 101 (shown by a dashed line) that supports the lamp units (Hi and Lo). The aiming driver module 90 includes a drive mechanism and a control unit (not shown) for moving the aiming screw 102 in the forward / rearward direction, and a metal case 92 that houses the drive mechanism and control unit. The metal case 92 is fixed to the sixth beam 66 by, for example, upper and lower fixing portions 93 with screws so that the longitudinal length of the case is arranged in the vertical direction, which is the axial direction of the sixth beam 66. In this way, the beams, which serve as compression members of the truss structure, actively support the internal structure of the lamp, thereby making it possible to further increase the rigidity of the truss structure of the lamp body 2 and thereby making the lamp body 2 thinner and lighter. Note that, although the external shape of the internal structure of the lamp is described as a metal case in the embodiments, the case material may be, for example, resin, and is not limited to a rectangular parallelepiped shape. The external shape of the internal structure of the lamp may deviate from the shape of the case, as long as it is a structure large enough and strong enough to reinforce the beams.

[0041] Although preferred embodiments of the present invention have been described above, the above-described embodiments are merely examples of the present invention, and combinations thereof based on the knowledge of those skilled in the art are possible, and such combinations are also within the scope of the present invention. In particular, the extension direction and shape of each beam disclosed in this specification are merely examples, and other types of truss structures may be used as long as a truss structure based on a triangle is formed. Accordingly, the arrangement of the internal structures of the lamp fixture disclosed in this specification is merely an example, and the arrangement of the internal structures of the lamp fixture may be suitably changed depending on the truss structure formed in the lamp body. [Explanation of symbols]

[0042] 1: Vehicle lighting fixtures 2: Lamp body 3: Seal groove 4: Front cover 6: Back wall (container side) 7: Ceiling surface (container surface) 8: Bottom surface (container surface) 9: Side (container surface) 31~32: Unit mounting holes 41-43: Aiming member mounting holes 61~67: Beam 50: Light driver module (structure inside the lamp) 80: Bead part (swell) 90: Aiming driver module (structure inside the lamp) S:Lamp room

Claims

1. The lamp comprises a container-shaped lamp body having an opening at the front, a front cover attached to the front opening of the lamp body to define a lamp chamber therein, and an internal structure of the lamp that is disposed within the lamp chamber, a plurality of beams, each of which is formed by a part of the vessel surface of the lamp body and has a cross section of a substantially arc-shaped, extending in a truss shape on the vessel surface of the lamp body; At least one of the beams supports the internal structure of the lamp fixture. A vehicle lamp characterized by:

2. The internal structure of the lamp is disposed on a beam on which an axial force in a compressive direction acts.

2. A vehicle lamp according to claim 1.

3. The structure inside the lamp is long, and the longitudinal direction of the structure inside the lamp is aligned with the axial direction of the beam.

2. A vehicle lamp according to claim 1.

4. At least one undulation is formed in the longitudinal direction of the lamp internal structure on the container surface near the beam that supports the lamp internal structure.

4. A vehicle lamp according to claim 3.

5. The lamp internal structure is fixed so as to be coupled to a container surface other than the container surface having a beam supporting the lamp internal structure.

2. A vehicle lamp according to claim 1.

Images