Vehicle headlight

Abstract

A vehicle headlight (1) is provided with a lamp unit (10), a leveling unit (30) fixed to the lamp unit (10), and a bracket (B2) for rotatably supporting the lamp unit (10) and the leveling unit (30).

Description

Vehicle headlights

[0001] The present disclosure relates to a vehicle headlamp.

[0002] Conventionally, there has been known a technique for adjusting the optical axis of a lamp unit in the vertical direction. For example, the lamp unit is supported by a support part provided above the lamp unit, and an actuator operating part provided below the lamp unit is caused to move linearly in the horizontal direction. This causes the lamp unit to rotate around the support part, thereby adjusting the optical axis of the lamp unit in the vertical direction.

[0003] Also, there is known a vehicle headlamp having a structure in which an optical unit is suspended from above a housing. For example, Patent Document 1 listed below discloses a vehicle headlamp having a structure in which an optical unit suspended from above a housing is rotated by a leveling actuator or a swivel actuator.

[0004] Also, there is known a vehicle headlamp having a structure in which an optical unit is suspended from above a housing. For example, Patent Document 1 listed below discloses a vehicle headlamp having a structure in which an optical unit suspended from above a housing is rotated by a leveling actuator or a swivel actuator.

[0005] Japanese Patent Application Laid-Open No. 2022-113788

[0006] However, in vehicle headlamps such as those described in Patent Document 1, the relationship between the distance the actuator operating part moves linearly and the angle at which the lamp unit rotates varies depending on the vehicle model, so adjusting the optical axis of the lamp unit requires a different design for each vehicle model.

[0007] An object of the present disclosure is to provide a vehicle headlamp that is easy to design and does not require different designs for each vehicle model.

[0008] Furthermore, the assembly process for the above-mentioned vehicle headlamp requires a step of fixing the actuator to the housing and a step of assembling the main unit including the optical unit to the housing. Furthermore, in addition to the actuator and the main unit, components such as an optical adjustment screw that supports and rotates the main unit on the housing must be attached to the housing, and the housing must have a complex shape to accommodate these attachments. Furthermore, because the optical adjustment screw is inserted from the back of the housing, a waterproof O-ring or the like is required at the insertion portion of the optical adjustment screw.

[0009] An object of the present disclosure is to provide a vehicle headlamp that is easy to assemble and does not require waterproofing components.

[0010] Furthermore, when the vehicle vibrates up and down, the vehicle headlamp is unable to maintain the orientation of the optical unit, which may cause the illumination range of the optical unit to fluctuate.

[0011] The present disclosure aims to improve the accuracy of aiming and leveling by always applying a rotational force to a lamp unit in a predetermined direction.

[0012] A vehicle headlamp according to one aspect of the present disclosure includes: a lamp unit; a leveling unit fixed to the lamp unit; and a bracket that rotatably supports the lamp unit and the leveling unit.

[0013] A vehicle headlamp according to another aspect of the present disclosure includes a housing and a main unit, the main unit including a leveling unit, a swivel unit, an optical unit, and a first bracket, and the main unit is attached to the housing by the first bracket.

[0014] A vehicle headlamp according to another aspect of the present disclosure includes a lamp unit and a leveling unit, wherein the leveling unit has a drive unit that rotates the lamp unit around a leveling axis, and when the drive unit is in a non-driven state, a rotational force acts on the lamp unit around the leveling axis due to the lamp unit's own weight.

[0015] According to the present disclosure, it is possible to provide a vehicle headlamp that is easy to design, without the need for different designs for each vehicle model.

[0016] Furthermore, according to the present disclosure, it is possible to provide a vehicle headlamp that is easy to assemble and does not require waterproofing components.

[0017] Furthermore, according to the present disclosure, a rotational force is always applied to the lamp unit in a predetermined direction, thereby improving the accuracy of aiming and leveling.

[0018] 16 is a conceptual diagram of a vehicle headlamp according to an embodiment of the present disclosure. FIG. 17 is a perspective view of a lamp unit, a leveling unit, a swivel unit, and a lamp bracket. FIG. 18 is an exploded perspective view of a main unit. FIG. 19 is an exploded perspective view of a swivel unit. FIG. 20 is a diagram illustrating an attachment structure between a first bracket, a swivel unit, and a first spline shaft. FIG. 21 is a perspective view of a first spline shaft. FIG. 22 is a cross-sectional view of a first output gear and a first spline shaft in a cross section perpendicular to the swivel axis direction. FIG. 23 is a perspective view of a lamp unit and a leveling unit. FIG. 24 is a perspective view of a removal jig used when removing a first spline shaft. FIG. 25 is a diagram illustrating the structure of a screw inserted into a screw attachment portion of a leveling unit and a boss portion of a lamp bracket. FIG. 26 is a cross-sectional view of a state in which the screw shown in FIG. 10 is inserted into a screw attachment portion of a leveling unit and a boss portion of a lamp bracket. FIG. 27 is an enlarged view of a state in which the screw shown in FIG. 10 is inserted into a boss portion. FIG. 28 is a horizontal partial cross-sectional view of a state in which the main unit is attached to a housing in FIG. 2. FIG. 29 is a perspective view of a vehicle headlamp according to a second embodiment. FIG. 29 is a side view of a left subunit. FIG. 29 is a cross-sectional view of the left subunit shown in FIG. 25 taken along line XVI-XVI.

[0019] In the following description, front, rear, left, right, top and bottom are defined as directions seen by a passenger in a vehicle equipped with a vehicle headlamp. Unless otherwise specified, front, rear, left, right, top and bottom are defined when the vehicle headlamp is oriented to irradiate light in front of the vehicle. In addition, a front view refers to a view of the vehicle headlamp from the front.

[0020] <First Embodiment> (Overall Configuration) Fig. 1 is a conceptual diagram of a vehicle headlamp according to an embodiment of the present disclosure. As shown in Fig. 1, the vehicle headlamp 1 includes a housing 100 and an outer lens 200 made of a translucent material that forms a lamp chamber together with the housing 100. The vehicle headlamp 1 includes a lamp unit 10, a swivel unit 20, a leveling unit 30, and an extension Sa within the lamp chamber. In the following description, the combined unit of the lamp unit 10, the swivel unit 20, and the leveling unit 30 will be referred to as a main unit M.

[0021] The extension Sa or decorative part is provided between the outer lens 200 and the main unit M, and is a component that prevents the parts inside the lamp chamber and the inner surface of the housing 100 from being visible from the outside through the outer lens 200, thereby enhancing the aesthetic appearance of the vehicle headlamp 1.

[0022] The swivel unit 20 rotates the lamp unit 10 and the leveling unit 30 about a swivel axis L1 extending in the vertical direction relative to the housing 100.

[0023] The leveling unit 30 supports the lamp unit 10 so as to be rotatable about a leveling axis L2 extending in the left-right direction relative to the swivel unit 20.

[0024] The lamp unit 10 emits a high beam light distribution pattern and a low beam light distribution pattern. The lamp unit 10 includes a light source 17, optical components such as a reflector and a lens that project light emitted from the light source 17 forward, a heat sink, and a lamp bracket 14 to which these components are attached (see FIG. 2 , described later). While the illustrated example shows an example in which a single lens 16 is mounted, multiple lenses or multiple reflectors may be mounted. Furthermore, either a single light source 17 or multiple light sources 17 may be provided.

[0025] In the vehicle headlamp 1 of the first embodiment, a single lamp unit 10 is attached to a housing 100 via a swivel unit 20 and a leveling unit 30 so as to be displaceable relative to the housing 100 .

[0026] 2 is a perspective view of the lamp unit 10, the leveling unit 30, the swivel unit 20, and the lamp bracket 14. The lamp unit 10, the leveling unit 30, and the swivel unit 20 are connected to one another to form a single main unit M. The front surface of the housing 100 is provided with convex mounting portions 110 (110U, 110R, 110L) that protrude forward. In the illustrated example, three mounting portions 110U, 110R, and 110L are provided. The main unit M is attached to the housing 100 via these mounting portions 110U, 110R, and 110L.

[0027] (Main Unit M) Fig. 3 is an exploded perspective view of the main unit M. As shown in Fig. 2 and Fig. 3, the main unit M has a first bracket B1, a first spline shaft S1, a swivel unit 20, a second bracket B2, a second spline shaft S2, a leveling unit 30, and a lamp unit 10. For convenience of drawing, Fig. 3 shows the outline shapes of the first spline shaft S1 and the second spline shaft S2.

[0028] (First Bracket B1) The first bracket B1 is fixed to the housing 100. The first bracket B1 has three mounting portions 11 (11U, 11R, 11L). The mounting portions 11 are portions that extend in the front-rear direction or the left-right direction. The mounting portions 11 are provided with insertion holes 11H therein into which the mounting portions 110 of the housing 100 are inserted. By inserting the mounting portions 110 of the housing 100 into the mounting portions 11 of the first bracket B1, the first bracket B1 is fixed to the housing 100 so that it cannot be displaced.

[0029] In the illustrated example, the mounting portion 11 is composed of an upper mounting portion 11U, and left and right mounting portions 11L and 11R that are provided below the upper mounting portion 11U. In a front view of the lamp unit 10, the right mounting portion 11R is located to the right of the left mounting portion 11L. In the illustrated example, in a front view of the lamp unit 10, the upper mounting portion 11U, the left mounting portion 11L, and the right mounting portion 11R are located at the vertices of an equilateral triangle.

[0030] The upper mounting portion 11U and the left mounting portion 11L are connected by a left beam portion 12L. The upper mounting portion 11U and the right mounting portion 11R are connected by a right beam portion 12R. A plate-shaped bottom portion 13 extending in the front-rear and left-right directions is provided between the left mounting portion 11L and the right mounting portion 11R. This bottom portion 13 is provided with a through-hole 13H that penetrates in the up-down direction. Note that a lance structure can be used to fit the mounting portion 110 and the mounting portion 11. The lance structure positions the mounting portion 110 and the mounting portion 11 at predetermined positions relative to each other.

[0031] (First Spline Shaft S1) The first spline shaft S1 is fixed to the bottom 13 of the first bracket B1. The first spline shaft S1 is a hollow shaft extending along the swivel axis L1 that extends in the up-down direction. The first spline shaft S1 passes through a through-hole 13H in the bottom 13 of the first bracket B1 from below, and an upper portion of the first spline shaft S1 protrudes upward from the bottom 13 of the first bracket B1 and is connected to the swivel unit 20. The first spline shaft S1 has a flat, ring-shaped flange 22 that extends in a direction perpendicular to the swivel axis L1. When the first spline shaft S1 is fixed to the bottom 13, the flange 22 engages with the bottom 13, forming an integrated unit that is unable to move relative to the swivel axis L1.

[0032] (Swivel unit 20) The swivel unit 20 rotates the lamp unit 10 about a swivel axis L1 extending in the vertical direction. The swivel unit 20 rotates the optical axis of the lamp unit 10 in the horizontal direction. The swivel unit 20 is attached to the first spline shaft S1 so as to be rotatable about the swivel axis L1. The swivel unit 20 engages with the first spline shaft S1 above the bottom 13 of the first bracket B1.

[0033] 4 is an exploded perspective view of the swivel unit 20. As shown in FIG. 4, the swivel unit 20 has a first casing 21 that includes a first motor MO, a first reduction gear unit D, and a first circuit board C.

[0034] The first casing 21 has a first case body 21A, a partition plate 21B, and a second case body 21C. The first case body 21A and the partition plate 21B form a circuit board accommodating chamber CR, and the second case body 21C and the partition plate 21B form a motor accommodating chamber MR.

[0035] The first circuit board C is accommodated in the board accommodation chamber CR. The first motor MO and the first reduction gear unit D are accommodated in the motor accommodation chamber MR. The output shaft Lo of the first motor MO transmits torque to the first reduction gear unit D. The first reduction gear unit D is composed of a first gear T1, a second gear T2, a third gear T3, and a first output gear TO1. The first gear T1 meshes with the output shaft Lo of the first motor MO and the second gear T2. The second gear T2 meshes with the first gear T1 and the third gear T3. The third gear T3 meshes with the second gear T2 and the first output gear TO1.

[0036] The first output gear TO1 is a cylindrical member extending along the swivel axis L1 shown in Fig. 3. The first output gear TO1 has, on a part of its outer circumferential surface, a tooth surface (first gear) TS that meshes with the third gear T3. The first gear T1, the second gear T2, and the third gear T3 are disposed at positions overlapping with the outer circumferential surface of the first output gear TO1 in the direction of extension of the swivel axis L1.

[0037] The first output gear TO1 is fixed to the first spline shaft S1 shown in Figure 3 and meshes with the third gear T3. The rotation axes of the first gear T1, the second gear T2, the third gear T3, and the first output gear TO1 are all parallel to the swivel axis L1. The torque of the first motor MO is transmitted to the first output gear TO1 via the first gear T1, the second gear T2, and the third gear T3.

[0038] (Axial Fixation) Figure 5 is a diagram showing the attachment structure of the first bracket B1, swivel unit 20, and first spline shaft S1. Figure 5 shows a cross section along the swivel axis L1. The first output gear TO1 is provided inside the first casing 21 so as to be rotatable around the swivel axis L1 but not displaceable in the direction of the swivel axis L1.

[0039] 4, the first output gear TO1 is a hollow member into which the first spline shaft S1 can be inserted. A window W penetrating radially is provided in a portion of the outer circumferential surface of the first output gear TO1. Because the first output gear TO1 is a hollow member, it is possible to ensure the rigidity of the first output gear TO1 and to reduce its weight.

[0040] Fig. 6 is a perspective view of the first spline shaft S1. As shown in Fig. 6, the first spline shaft S1 has a flat, ring-shaped flange 22 extending in a direction perpendicular to the swivel axis L1, and legs 23 extending from the flange 22 along the swivel axis L1. A locking claw 23L is provided at the axial tip of the leg 23. The leg 23 is an elongated portion in the axial direction, and the tip is elastically deformable in the radial direction.

[0041] Returning to Figure 5, the first output gear TO1 and the through hole 13H provided in the bottom portion 13 of the first bracket B1 are positioned coaxially, and the first spline shaft S1 is passed through the through hole 13H of the first bracket B1 and inserted up to the first output gear TO1 so that the bottom portion 13 of the first bracket B1 is sandwiched between the swivel unit 20 and the flange portion 22 of the first spline shaft S1.

[0042] As the first spline shaft S1 is inserted into the first output gear TO1, the tips of the legs 23 in the insertion direction are pressed against the inner circumferential surface of the first output gear TO1 and elastically deform radially inward. When the first spline shaft S1 is further inserted into the first output gear TO1, the locking pawls 23L fit into the windows W of the first output gear TO1, as shown in Figure 5, and the elastic radially inward deformation of the legs 23 is released. With the locking pawls 23L fitted into the windows W in this manner, the locking pawls 23L come into contact with the windows W and the tips of the first insertion guide portions 25 abut against stepped portions formed on the inner surface of the first output gear TO1, preventing the first spline shaft S1 from moving in the direction of the swivel axis L1.

[0043] (Circumferential and Radial Fixation) As shown in FIG. 6 , the first spline shaft S1 has a plurality of first mounting tongues FT1 and a plurality of second mounting tongues FT2 that protrude from the flange portion 22 in the direction of the swivel axis L1. The plurality of first mounting tongues FT1 are provided at intervals in the circumferential direction. Each second mounting tongue FT2 is provided between the first mounting tongues FT1 in the circumferential direction. In this embodiment, three first mounting tongues FT1 and three second mounting tongues FT2 are formed in the circumferential direction, but the number of each of the first mounting tongues FT1 and the second mounting tongues FT2 is not limited to three.

[0044] Each first mounting tongue FT1 has a leg portion 23 with a locking claw 23L at its tip, a circumferential abutment portion 24, and a first insertion guide portion 25. A pair of circumferential abutment portions 24 are provided on both circumferential sides of the leg portion 23, sandwiching the leg portion 23. The circumferential abutment portions 24 extend from the flange portion 22 to a length greater than the length of the leg portion 23. The pair of circumferential abutment portions 24 extend at an angle such that the distance between them decreases with increasing distance from the flange portion 22. Ends of the circumferential abutment portions 24 opposite the flange portion 22 are connected in the circumferential direction by the first insertion guide portion 25. The locking claw 23L at the tip of the leg portion 23 is not connected to the first insertion guide portion 25. The outer peripheral surface of the first insertion guide portion 25 opposite the flange portion 22 has a conical shape whose outer diameter decreases with increasing distance from the flange portion 22. In the illustrated example, pairs of circumferential abutment portions 24 are provided at three locations spaced apart in the circumferential direction of the first spline shaft S1.

[0045] The second mounting tongue FT2 has a main body 26 that protrudes from the flange 22 in the direction of the swivel axis L1, and a second insertion guide 27 that is provided at the tip of the main body 26. Similar to the first insertion guide 25, the outer peripheral surface of the second insertion guide 27 has a conical shape whose outer diameter decreases with increasing distance from the flange 22.

[0046] 7 is a cross-sectional view of the first output gear TO1 and the first spline shaft S1 taken along a cross section perpendicular to the swivel axis L1. The first spline shaft S1 is positioned so that the locking pawls 23L engage with the window portions W of the first bracket B1. Because the locking pawls 23L contact the wall surfaces of the window portions W, the first spline shaft S1 and the first output gear TO1 are prevented from rotating relative to each other around the swivel axis L1.

[0047] 7, the through hole TOH of the first output gear TO1 does not have a circular cross section, and the first output gear TO1 has multiple protrusions P that protrude radially inward. The first mounting tongues FT1 of the first spline shaft S1 fit between the circumferential spaces between these protrusions P. Conversely, the protrusions P of the first output gear TO1 fit between the circumferential spaces between the multiple first mounting tongues FT1 of the first spline shaft S1, and the multiple main body portions 26 of the first spline shaft S1 are engaged with the multiple protrusions P of the first output gear TO1, respectively. The circumferential abutment portions 24 of the first spline shaft S1 abut against the side surfaces of the protrusions P. This prevents relative rotation between the first spline shaft S1 and the first output gear TO1 about the swivel axis L1.

[0048] 6, the pair of circumferential abutment portions 24 of the first spline shaft S1 are inclined so that the distance between them becomes narrower as they move away from the flange portion 22. As the first spline shaft S1 is inserted into the first output gear TO1, the force with which the circumferential abutment portions 24 are pressed against the protrusion P increases, preventing circumferential backlash from occurring between the first spline shaft S1 and the first output gear TO1.

[0049] 7 , when the first spline shaft S1 is not inserted into the first output gear TO1, the outer diameter of the second mounting tongue FT2 of the first spline shaft S1 and the outer diameters of the locking claws 23L, first insertion guide portions 25, and second insertion guide portions 27 of the first mounting tongue FT1 are slightly larger than the inner diameter of the insertion hole of the first output gear TO1. Therefore, when the first spline shaft S1 is inserted into the first output gear TO1, the first spline shaft S1 is elastically deformed radially inward. In this state, an elastic restoring force acts to displace the second mounting tongue FT2, the locking claws 23L of the first mounting tongue FT1, the first insertion guide portions 25, and the second insertion guide portions 27 radially outward. In other words, when the first spline shaft S1 is inserted into the first output gear TO1, an elastic restoring force acts on the first spline shaft S1, pushing the inner surface of the insertion hole of the output gear radially outward, preventing radial play from occurring between the first spline shaft S1 and the first output gear TO1.

[0050] With this structure, the first spline shaft S1 and the first output gear TO1 are fixed so that they cannot be displaced relative to each other. The first output gear TO1 is fixed to the first spline shaft S1, and the first spline shaft S1 is fixed to the housing 100 via the first bracket B1.

[0051] (Second Bracket B2) Returning to Figure 3, the second bracket B2 will be described. The second bracket B2 is fixed to the swivel unit 20. The second bracket B2 supports the leveling unit 30 so that it can rotate about the leveling axis L2. The second bracket B2 is located above the swivel unit 20. The second bracket B2 has a swivel fixing portion 28 that is fixed to the first casing 21 of the swivel unit 20, and a leveling support portion 29A to which the second spline shaft S2 is fixed.

[0052] In the illustrated example, the second bracket B2 is a plate-like member that is approximately U-shaped when viewed from the front. The second bracket B2 has a swivel fixing portion 28 located at the bottom of the U, a leveling support portion 29A, and an auxiliary support portion 29B. The leveling support portion 29A is provided on the left side of the swivel fixing portion 28. The auxiliary support portion 29B is provided on the right side of the swivel fixing portion 28. The swivel fixing portion 28 is a plate-like portion that extends in the front-rear and left-right directions. The leveling support portion 29A and the auxiliary support portion 29B are plate-like portions that extend in the front-rear and up-down directions.

[0053] The swivel fixing portion 28 of the second bracket B2 is provided with a fitting hole 28H that penetrates in the vertical direction. This fitting hole 28H fits into a fitting portion 20L provided on the upper surface of the first casing 21 of the swivel unit 20, thereby fixing the second bracket B2 and the swivel unit 20 together.

[0054] The leveling support portion 29A of the second bracket B2 is provided with a support hole 29H that penetrates in the left-right direction and extends along the leveling axis L2.

[0055] The second spline shaft S2 has the same structure as the first spline shaft S1. That is, the second spline shaft S2 fixes the positional relationship between the second bracket B2 and the leveling unit 30 in the same manner as the first spline shaft S1 fixes the positional relationship between the first bracket B1 and the swivel unit 20.

[0056] The leveling unit 30 has the same structure as the swivel unit 20. The motor of the swivel unit 20 differs from the motor of the leveling unit 30 only in output torque and size, and the components are the same. The reduction gear unit of the swivel unit 20 differs from the reduction gear unit of the leveling unit 30 in terms of gear size, number of teeth, number of gears, reduction ratio, etc., but they are common in that they are both configured with multiple gears.

[0057] In this way, by mounting the first reduction gear unit D on the leveling unit 30, the sliding resistance between the gears of the first reduction gear unit D is large, which prevents the lamp unit 10 from losing its vertical position due to vehicle vibrations and maintains the vertical position of the lamp unit 10. Furthermore, by sharing parts between the leveling unit 30 and the swivel unit 20, manufacturing costs can be reduced.

[0058] The connection structure between the second spline shaft S2, the leveling support portion 29A of the second bracket B2, and the leveling unit 30 is the same as the connection structure between the first spline shaft S1, the first bracket B1, and the swivel unit 20 described above, so detailed description thereof will be omitted.

[0059] (Fixing Structure of Lamp Unit 10 and Leveling Unit 30) Figure 8 is a perspective view showing the lamp unit 10 and the leveling unit 30. As shown in Figure 8, the lamp unit 10 includes a lamp bracket 14, a lens holder 15, a projection lens 16, and a light source 17. In the example shown, the lamp bracket 14 is made of metal and has fins that function as a heat sink in addition to supports that support the light source 17 and the lens holder 15. The lens holder 15 is attached to the front of the lamp bracket 14. This lens holder 15 supports the projection lens 16.

[0060] The lamp bracket 14 has a base portion 14A to which the lens holder 15 is attached, and a leveling support plate portion 14B, which is a plate-shaped member extending in the up-down and front-rear directions and provided on the side of the lamp bracket 14. The leveling support plate portion 14B has a fitting hole (insertion hole) 14D with a recess 14C formed in its inner peripheral surface. The second casing 31 of the leveling unit 30 has an insertion portion 31A that is inserted into the fitting hole 14D. The outer periphery of the insertion portion 31A is formed with a fitting portion (claw portion) 31B that can pass through the recess 14C. This fitting hole 14D is provided coaxially with the leveling axis L2.

[0061] With the insertion portion 31A inserted into the fitting hole 14D and the fitting portion 31B passing through the recess 14C, the lamp unit 10 is rotated relative to the leveling unit 30 along the circumferential direction of the insertion portion 31A, whereby the fitting portion 31B fits into the leveling support plate portion 14B. This fit between the fitting portion 31B and the leveling support plate portion 14B prevents the lamp unit 10 from moving along the leveling axis L2 relative to the leveling unit 30.

[0062] The leveling support plate 14B also has a boss 14F that protrudes toward the leveling unit 30. A screw hole (first screw hole) 14G is provided on the tip surface of the boss 14F. A screw mounting portion 31D with a screw hole (second screw hole) 31C is also provided on the second casing 31 of the leveling unit 30. The leveling unit 30 and the lamp unit 10 are fixed together by threading a screw that passes through the screw mounting portion 31D of the leveling unit 30 into the boss 14F of the leveling support plate 14B.

[0063] As described above, in vehicle headlamps such as those described in Patent Document 1, the dimensions of the aiming structure differ depending on the vehicle model, and therefore the relationship between the amount of change in the optical axis of the lamp unit 10 and the amount of stroke of the linearly moving actuator differs depending on the vehicle model, making the design complicated.

[0064] In contrast, in the vehicle headlamp 1 according to the present disclosure, the leveling unit 30, which is a member that supports the lamp unit 10, rotates about the leveling axis L2. As a result, the angle at which the leveling unit 30 rotates matches the angle at which the lamp unit 10 rotates, and therefore, there is no need to design differently for each vehicle model in order to adjust the optical axis of the lamp unit 10 in the up-down direction, making design easier.

[0065] Furthermore, because the leveling axis L2 overlaps with the lamp unit 10, the distance between the leveling axis L2 and the first motor MO is shorter than in conventional leveling structures. Therefore, even when rotated by the same angle, the length of the arc-shaped displacement path of the lamp unit 10 is shorter than in conventional structures, making it less likely for the lamp unit 10 to interfere with surrounding components such as the extension Sa. In other words, the clearance for arranging peripheral components such as the extension Sa relative to the lamp unit 10 can be designed to be small, resulting in a design with a good appearance.

[0066] In this embodiment, the leveling unit 30 and the lamp unit 10 are fixed together by inserting screws into the screw holes 31C of the screw attachment portions 31D and the screw holes 14G of the boss portions 14F, but the fixing structure is not limited to the above. For example, instead of screws, elastically deformable clips may be inserted into the screw holes 31C and the screw holes 14G.

[0067] <Operation> When the swivel unit 20 is activated, the first motor MO generates torque that rotates the first output gear TO1 relative to the first casing 21. The first output gear TO1 is fixed to the first bracket B1 via the first spline shaft S1, and the first bracket B1 is also fixed to the housing 100. In other words, the first output gear TO1 is fixed to the housing 100. As a result, when torque is generated in the first output gear TO1, the first motor MO and the first casing 21 supporting the first motor MO rotate about the swivel axis L1 due to a reaction force. Because the lamp unit 10 is fixed to the first casing 21 via the second bracket B2 and the leveling unit 30, the lamp unit 10 also rotates together with the first casing 21 about the swivel axis L1. As described above, when the swivel unit 20 is activated, the lamp unit 10 rotates about the swivel axis L1, and the optical axis of the lamp unit 10 swivels about the swivel axis L1.

[0068] The operation of the leveling unit 30 is basically the same as that of the swivel unit 20. When the leveling unit 30 is operated, the motor of the leveling unit 30 generates torque that rotates the output gear relative to the second casing 31 of the leveling unit 30. The output gear of the leveling unit 30 is fixed to the second bracket B2 via the second spline shaft S2. The second bracket B2 is fixed to the swivel unit 20. In other words, the output gear of the leveling unit 30 is fixed to the swivel unit 20. As a result, when torque is generated in the output gear of the leveling unit 30, the motor of the leveling unit 30 and the second casing 31 supporting the motor are rotated around the leveling axis L2 by a reaction force. Because the lamp unit 10 is fixed to the second casing 31 of the leveling unit 30 via the lamp bracket 14, the lamp unit 10 also rotates together with the second casing 31 around the leveling axis L2. As described above, when the leveling unit 30 is activated, the lamp unit 10 rotates around the leveling axis L2, and the optical axis of the lamp unit 10 is leveled around the leveling axis L2.

[0069] <Others> According to the vehicle headlamp 1 of the present disclosure, when the main unit M is assembled in advance, the first bracket B1 can be attached to the housing 100 together with the main unit M. This significantly improves work efficiency compared to when the lamp unit 10, swivel unit 20, leveling unit 30, etc. are attached to the housing 100 individually.

[0070] Furthermore, when the lamp unit 10, swivel unit 20, leveling unit 30, etc. are individually attached to the housing 100, the respective attachment positions will differ depending on the type of vehicle headlamp 1. However, according to the vehicle headlamp 1 of the present disclosure, when the type of vehicle headlamp 1 is different, only the attachment structure of the first bracket B1 to the housing 100 needs to be different, and the structure of the main unit M including the lamp unit 10, swivel unit 20, and leveling unit 30 can be made common among different types of vehicle headlamp 1. Alternatively, when the type of vehicle headlamp 1 is different, even the attachment structure of the first bracket B1 to the housing 100 can be made common, making it easy to standardize components.

[0071] Furthermore, when a screw is used to rotate the lamp unit 10 about the swivel axis L1 or the leveling axis L2, it is difficult to move the lamp unit 10 quickly. However, according to the vehicle headlamp 1 of the present disclosure, the swivel unit 20 and the leveling unit 30 change the optical axis of the lamp unit 10 using the first motor MO. Therefore, the optical axis of the lamp unit 10 can be moved more quickly than when an operator changes the optical axis of the lamp unit 10 by rotating a screw.

[0072] Furthermore, in conventional vehicle headlamps, unlike the vehicle headlamp 1 of the present disclosure, the optical axis of the vehicle headlamp is aligned using an aiming unit before shipping. However, with the vehicle headlamp 1 of the present disclosure, the aiming operation only requires setting the initial position of the first motor MO, so no aiming unit is required in addition to the swivel unit 20 and the leveling unit 30.

[0073] In the vehicle headlamp 1 of the present disclosure, a six-axis sensor (not shown) and a gyro sensor are mounted on the leveling unit 30. The leveling unit 30 is fixed to the lamp unit 10 and displaces together with the lamp unit 10. Therefore, the attitude of the lamp unit 10 can be directly detected by the six-axis sensor and the gyro sensor.

[0074] The six-axis sensor and gyro sensor may be mounted directly on the lamp unit 10, or may be mounted on the leveling unit 30 fixed to the lamp unit 10. If mounted on the leveling unit 30, they may be mounted on the circuit board CR. If the six-axis sensor and gyro sensor are mounted on the circuit board CR, the sensors can be easily fixed and powered on the circuit board.

[0075] 5, a removal guide portion 25R is provided on the inner peripheral surface of the leg portion 23. In the cross section shown in the figure, the removal guide portion 25R has a hook-like shape that protrudes radially inward from the inner peripheral surface of the leg portion 23 and is folded back toward the flange portion 22 at its tip. The inner peripheral surface of the hook-like barb at its tip is formed as an inclined surface whose diameter increases as it moves away from the flange portion 22 in the axial direction.

[0076] FIG. 9 is a perspective view of a removal jig SJ used when removing the first spline shaft S1 from the first output gear TO1. As shown in FIG. 9 , the removal jig SJ has a cylindrical base portion SJB and a cylindrical insertion portion SJI with a diameter smaller than that of the base portion SJB. The outer diameter of the insertion portion SJI is slightly smaller than the inner diameter of the inner peripheral surface of the first spline shaft S1. The tip of the insertion portion SJI of the removal jig SJ is provided with a plurality of removal tongue portions SJT spaced apart circumferentially and extending in the axial direction of the first spline shaft S1. The removal tongue portions SJT are arc-shaped portions when viewed axially. The inner diameter of the removal tongue portions SJT decreases in the clockwise direction. The clockwise tip of the removal tongue portion SJT is provided with a rotation stopper SJS that protrudes radially outward from the outer peripheral surface.

[0077] The procedure for removing the first spline shaft S1 from the swivel unit 20 and the first bracket B1 using the removal jig SJ will be described. First, the insertion portion SJI of the removal jig SJ is inserted into the first spline shaft S1, and the removal jig SJ is rotated counterclockwise until the leg portion 23 of the first spline shaft S1 abuts against the rotation stopper SJS. When the removal jig SJ is rotated counterclockwise, the inner peripheral surface of the removal tongue portion SJT comes into contact with the wall surface of the removal guide portion 25R of the first spline shaft S1. Because the inner diameter of the removal tongue portion SJT decreases in the clockwise direction, continuing to rotate the removal jig SJ clockwise pulls the removal guide portion 25R radially inward. When the removal guide portion 25R is pulled radially inward, the first mounting tongue FT1 of the first spline shaft S1 is displaced radially inward, and the locking pawl 23L disengages from the first output gear TO1. In this state, the removal jig can be pulled out together with the first spline shaft S1 from the swivel unit 20 and the first bracket B1.

[0078] 8 again, as described above, the second casing 31 of the leveling unit 30 and the lamp bracket 14 of the lamp unit 10 are fixed together. Furthermore, the second casing 31 and the second bracket B2 of the leveling unit 30 are slidably supported on the outer circumferential surface of the first output gear TO1 of the leveling unit 30. Furthermore, the first output gear TO1 is in contact with the outer circumferential surface of the second spline shaft S2.

[0079] Therefore, the lamp unit 10 is supported not only by the first reduction gear unit D provided in the leveling unit 30, but also by the second casing 31, first output gear TO1, first spline shaft S1, and second bracket B2 in the leveling unit 30. This reduces the load on the first reduction gear unit D, improving the durability of the first reduction gear unit D. Furthermore, the lamp unit 10 can be reliably supported by the second spline shaft S2 fixed to the second bracket B2, increasing the support rigidity of the lamp unit 10.

[0080] Furthermore, it is desirable that the outer diameter of the first output gear TO1 in the first reduction gear unit D and the outer diameter of the second spline shaft S2 inserted inside the first output gear TO1 be 10 mm or greater. In this way, when the outer diameters of the first output gear TO1 and the second spline shaft S2 are large, a wide contact area can be ensured between the second casing 31 and the first output gear TO1, and a wide contact area can be ensured between the first output gear TO1 and the second spline shaft S2. This reduces the surface pressure that each of the second casing 31, the first output gear TO1, and the second spline shaft S2 receives, thereby further improving the durability of the first reduction gear unit D, the first output gear TO1, and the second spline shaft S2.

[0081] (Structure of screws for fixing the lamp unit 10 and the leveling unit 30) Fig. 10 is a diagram showing the structure of the screw 41 inserted into the screw attachment portion 31D of the leveling unit 30 shown in Fig. 8 and the boss portion 14F of the lamp bracket 14. Fig. 11 is a cross-sectional view showing the state in which the screw 41 shown in Fig. 10 has been inserted into the screw attachment portion 31D of the leveling unit 30 and the boss portion 14F of the lamp bracket 14.

[0082] 10 , the screw 41 has a head 42 and a body 43. On the top surface of the head 42, i.e., the surface opposite to the body 43, a tool hole 42A, which is, for example, cross-shaped, and a slit 42B that curves along the side surface of the head 42 are formed.

[0083] The body 43 has a first body 44 and a second body 45 that extend along the longitudinal direction and face each other. The first body 44 and the second body 45 are connected at a base end on the head 42 side and are separated from each other at a tip end on the opposite side from the head 42. The first body 44 and the second body 45 are elastically deformable so that their tips approach each other.

[0084] 11 , if the insertion direction of the screw 41 into the screw attachment portion 31D and the boss portion 14F is defined as "direction X," the first body 44 has a first protruding portion 44A at its tip that protrudes in a direction perpendicular to the X direction and away from the second body 45. Furthermore, the first body 44 has a second protruding portion 44B that protrudes, on the base end side of the first protruding portion 44A, in a direction perpendicular to the X direction and away from the second body 45.

[0085] Similar to the first body 44, the second body 45 has a second protruding portion 45A at its tip end that protrudes in a direction perpendicular to the X direction and away from the first body 44. The second body 45 also has a second protruding portion 45B, located closer to the base end than the second protruding portion 45A, that protrudes in a direction perpendicular to the X direction and away from the first body 44. The first protruding portion 44A and the second protruding portion 45A have a tapered shape that narrows toward the tip end.

[0086] 12 is an enlarged view showing the state in which the screw 41 is inserted into the boss portion 14F. As shown in Fig. 12, two locking portions 14H are formed at the X-direction end of the boss portion 14F, protruding toward the radial center of the boss portion 14F.

[0087] The inner diameter of the screw hole 14G in the boss portion 14F gradually narrows along the X direction. Specifically, the boss portion 14F is provided with a spiral portion 14J that extends spirally along the inner wall of the screw hole 14G. The thickness of each spiral portion 14J gradually increases along the X direction.

[0088] 10, a tool is inserted into the tool hole 42A, and the screw 41 is inserted into the screw attachment portion 31D and the boss portion 14F while being rotated about an axis extending in the X direction. At this time, the first body 44 and the second body 45 of the screw 41 elastically deform in directions approaching each other.

[0089] As the screw 41 is further inserted, the first protrusion 44A and the second protrusion 45A are guided by the helical portion 14J and move closer to each other as they pass through the screw hole 14G. Then, when the first protrusion 44A and the second protrusion 45A have passed through the screw hole 14G, the second protrusion 44B and the second protrusion 45B come into contact with the locking portion 14H, as shown in FIG.

[0090] In this state, the head 42 abuts against the screw mounting portion 31D. As shown in Fig. 10, the head 42 has a slit 42B formed therein, and therefore, when the head 42 is in contact with the screw mounting portion 31D, the head 42 deforms to slightly reduce its diameter, and the elastic force of the head 42 increases the abutting force between the head 42 and the screw mounting portion 31D, preventing rattling of the screw 41 in a direction intersecting the X direction.

[0091] Furthermore, the surface of the first protrusion 44A facing the lamp bracket 14 and the surface of the second protrusion 45A facing the lamp bracket 14 are inclined surfaces whose diameters decrease toward the opposite side of the X direction. Therefore, even if the screw 41 attempts to separate from the lamp bracket 14, these inclined surfaces exert a force pulling the screw 41 in the X direction. It is preferable that the dimension from the end face of the head 42 on the X direction side to these inclined surfaces be slightly shorter than the sum of the thickness of the screw mounting portion 31D of the leveling unit 30 and the height of the boss portion 14F of the lamp bracket 14. This suppresses wobble of the screw 41 in the X direction. As a result, the positional relationship between the lamp unit 10 having the lamp bracket 14 and the leveling unit 30 having the screw mounting portion 31D can be more reliably fixed.

[0092] 2 , the housing 100 has at least three mounting portions 110U, 110R, and 110L that protrude toward the first bracket B1 and support the mounting portions 11U, 11R, and 11L, respectively, and a planar support portion 110S that connects the mounting portions 110U, 110R, and 110L to one another. The mounting portions 110U, 110R, and 110L are inserted into the mounting portions 11U, 11R, and 11L, respectively, to fix the main unit M to the housing 100. The planar support portion 110S and the left beam portion 12L and right beam portion 12R of the first bracket B1 are in surface contact with each other via curved surfaces. In this way, the planar support portion 110S and the left beam portion 12L and right beam portion 12R are in surface contact with each other at their curved surfaces, thereby preventing the left beam portion 12L and right beam portion 12R of the first bracket B1 from bending and deforming due to the weight of the main unit M.

[0093] 13 is a horizontal partial cross-sectional view taken along the cross section LH in FIG. 2 when the main unit M is fixed to the housing 100. As shown in FIG. 13, in a cross section intersecting the direction in which the left beam portion 12L and the right beam portion 12R are stretched, the left beam portion 12L, the right beam portion 12R, and the planar support portion 110S form a substantially hollow circular shape CS. In this way, the left beam portion 12L, the right beam portion 12R, and the planar support portion 110S form a semi-monocoque structure having a substantially hollow circular shape, which can suppress bending and deformation of the mounting portions 11U, 11R, and 11L of the first bracket B1.

[0094] (Connection between the output shaft Lo of the first motor MO, the first gear T1, the second gear T2, the third gear T3, and the first output gear TO1) Returning to FIG. 1 , the lamp unit 10 is disposed so that the center of gravity G of the lamp unit 10 is located away from the leveling axis L2. Therefore, a rotational force is constantly acting on the lamp unit 10 in a predetermined direction due to the weight of the lamp unit 10. At this time, the rotatable angle range of the lamp unit 10 is a range of less than ±5° from the horizontal direction centered on the leveling axis L2. Therefore, the rotation angle of the lamp unit 10 does not rotate to a direction perpendicular to the leveling axis L2. Therefore, even if the vehicle vibrates up and down, the attitude of the lamp unit 10 can be easily maintained.

[0095] Furthermore, because a rotational force is constantly acting on the lamp unit 10 in a predetermined direction, the output shaft Lo of the first motor MO and the first gear T1, the first gear T1 and the second gear T2, the second gear T2 and the third gear T3, and the third gear T3 and the first output gear TO1 are all connected without any play. As a specific example, at least a portion of the gear of the output shaft Lo and at least a portion of the gear of the first gear T1 are in contact with each other. Therefore, the frictional force between the gears makes it easier to maintain the posture of the lamp unit 10.

[0096] As described above, the vehicle headlamp 1 of the present disclosure includes the lamp unit 10, the leveling unit 30 fixed to the lamp unit 10, and the second bracket (bracket) B2 that rotatably supports the lamp unit 10 and the leveling unit 30. With this configuration, the angle at which the leveling unit 30 rotates matches the angle at which the lamp unit 10 rotates. Therefore, there is no need to design differently for each vehicle model to adjust the optical axis of the lamp unit 10 in the up-down direction, making the design easier.

[0097] Furthermore, in the vehicle headlamp 1, the leveling unit 30 has a first output gear (fixed portion) TO1 fixed to the second bracket B2, and a second casing (rotating portion) 31 that rotates about a leveling axis L2 relative to the first output gear TO1. The second casing 31 is fixed to the lamp unit 10. With this configuration, the space required to rotate the lamp unit 10 can be made smaller, compared to a configuration in which a support structure is provided above the lamp unit and a rotation mechanism is provided below the lamp unit, as in conventional vehicle headlamps, and the vehicle headlamp 1 can be made more compact.

[0098] In the vehicle headlamp 1, the first output gear TO1 fixed to the second bracket B2 is a shaft member extending along the leveling axis L2. The second casing 31, which rotates about the leveling axis L2, includes a first motor MO that rotates the second casing 31 relative to the first output gear TO1. With this configuration, the second casing 31 including the first motor MO can be rotated around the first output gear TO1.

[0099] Furthermore, in the vehicle headlamp 1, the first output gear TO1 is a hollow member along the leveling axis L2. With this configuration, it is easy to reduce the weight of the first output gear TO1 while ensuring its rigidity.

[0100] It is preferable that a sensor for measuring the rotation angle of the lamp unit 10 is provided in the leveling unit 30. Because the sensor rotates together with the lamp unit 10, the sensor can directly detect the rotation angle of the lamp unit 10. In this case, if the first output gear TO1 is a hollow member, the wiring extending from the sensor can be passed through the first output gear TO1, which serves as the center of rotation of the sensor. Even when the lamp unit 10 rotates, the wiring does not move significantly and is less likely to interfere with other members.

[0101] The vehicle headlamp 1 further includes a second spline shaft S2 that fixes the positional relationship between the first output gear TO1 and the second bracket B2, and the second spline shaft S2 is a hollow member. With this configuration, the weight of the second spline shaft S2 itself is suppressed, and the positional relationship between the leveling unit 30 and the second bracket B2 can be fixed using the second spline shaft S2, which has high rigidity against forces from any direction.

[0102] Furthermore, in the vehicle headlamp 1, the second casing 31 is slidably supported on the outer peripheral surface of the first output gear TO1 in the leveling unit 30. With this configuration, the lamp unit 10 fixed to the leveling unit 30 is supported not only by the first reduction gear unit D provided in the second casing 31, but also by the first reduction gear unit D and the outer peripheral surface of the first output gear TO1. This reduces the load on the first reduction gear unit D, and the durability of the first reduction gear unit D in the leveling unit 30 can be improved.

[0103] Furthermore, in the vehicle headlamp 1, the outer diameter of the first output gear TO1 is 10 mm or more. Since the outer diameter of the first output gear TO1 is sufficiently large, a large contact area can be ensured between the second casing 31 and the outer peripheral surface of the first output gear TO1. This reduces the surface pressure that each of the second casing 31 and the first output gear TO1 receives, further improving the durability of the first reduction gear unit D and the first output gear TO1 provided in the second casing 31.

[0104] In the vehicle headlamp 1, the lamp unit 10 includes a leveling support plate (plate-shaped member) 14B having a fitting hole (insertion hole) 14D with a recess 14C formed on its inner circumferential surface, and the leveling unit 30 includes an insertion portion 31A that is inserted into the fitting hole 14D. The insertion portion 31A has a fitting portion (claw portion) 31B formed on its outer periphery that can penetrate the recess 14C. When the insertion portion 31A is inserted into the fitting hole 14D and the fitting portion 31B penetrates the recess 14C, the lamp unit 10 is rotated relative to the leveling unit 30 along the circumferential direction of the insertion portion 31A, whereby the fitting portion 31B engages with the leveling support plate 14B. This configuration facilitates the assembly of the lamp unit 10 and the leveling unit 30.

[0105] Furthermore, in the vehicle headlamp 1, a leveling support plate portion 14B is provided on the side surface of the lamp unit 10. With this configuration, the assembly work of the lamp unit 10 and the leveling unit 30 can be further facilitated.

[0106] In the vehicle headlamp 1, a screw hole (first screw hole) 14G is formed in the lamp unit 10. A screw hole (second screw hole) 31C is formed in the leveling unit 30 at a position corresponding to the screw hole 14G when the lamp unit 10 is attached. With this configuration, the lamp unit 10 and the leveling unit 30 can be more reliably fixed together by passing a screw 41 through the screw hole 14G and the screw hole 31C.

[0107] Furthermore, in the vehicle headlamp 1, the first output gear TO1 has a tooth surface (first gear) TS, and the second casing 31 has a first reduction gear unit (reduction gear) D that meshes with the tooth surface TS. The first reduction gear unit D is provided at a position overlapping with the first output gear TO1 in the direction in which the leveling axis L2 extends. With this configuration, the first output gear TO1 and the first reduction gear unit D at least partially overlap with each other in the direction in which the leveling axis L2 extends, thereby making it possible to reduce the size of the leveling unit 30.

[0108] In the above-described vehicle headlamp 1, the first output gear TO1 of the leveling unit 30 corresponds to a fixed part that is fixed to the second bracket B2 by the second spline shaft S2. Also, the second casing 31 of the leveling unit 30 that is fixed to the lamp unit 10 corresponds to a rotating part that rotates about the leveling axis L2 by receiving the operating force of the first motor MO.

[0109] However, this configuration is not limited to this, and for example, the second casing 31 may correspond to a fixed part fixed to the second bracket B2, and the first output gear TO1 may correspond to a rotating part that rotates around the leveling axis L2.

[0110] Furthermore, in the above description, the second bracket B2 has been described as being U-shaped in front view, but the shape of the second bracket B2 is not limited to this. For example, the second bracket B2 may have a square frame shape in front view. That is, the second bracket B2 may have a shape in which an upper frame portion that connects the upper ends of the leveling support portions 29A and the auxiliary support portions 29B is added to the U-shaped second bracket B2 described above. This upper frame portion may have a support portion that is supported rotatably about the swivel axis L1 relative to the housing 100. This support portion and the first spline shaft S1 can support the second bracket B2 without wobbling about the swivel axis L1.

[0111] The vehicle headlamp 1 also has a housing 100 and a main unit M, the main unit M having a leveling unit 30, at least one swivel unit 20, at least one optical unit, and a first bracket B1, and the main unit M is attached to the housing 100 by the first bracket B1.

[0112] This makes it possible to provide a vehicle headlamp that is easy to assemble and does not require waterproofing components.

[0113] Furthermore, as shown in Figures 2 and 3, in the vehicle headlamp 1 of the present disclosure, the first bracket B1 has at least three convex supported portions (the above-mentioned mounting portions in the present disclosure), and the housing 100 has at least three convex supporting portions (the above-mentioned mounting portions 110U, 110R, 110L in the present disclosure) that protrude toward the first bracket B1 and each support the convex supported portion, and a planar supporting portion 110S that connects the plurality of convex supporting portions to one another.

[0114] This makes it possible for the planar supporting portion to prevent the convex supported portion of the first bracket from being bent and deformed due to the weight of the main unit itself.

[0115] Furthermore, as shown in FIG. 2 , in the vehicle headlamp 1 of the present disclosure, the main unit M is fixed to the housing 100 by inserting the plurality of convex supporting portions into the plurality of convex supported portions, respectively.

[0116] This makes it easier to attach the main unit to the housing, and reduces the number of parts such as screws.

[0117] Furthermore, as shown in FIG. 3 , in the vehicle headlamp 1 of the present disclosure, the plurality of convex supported portions include upper convex supported portions (the upper mounting portion 11U in the present disclosure described above) and lower convex supported portions (the left mounting portion 11L and the right mounting portion 11R in the present disclosure described above) located below the upper convex supported portions.

[0118] In this way, by having the multiple convex supported portions comprise upper convex supported portions and lower convex supported portions, it is possible to prevent the convex supported portions of the first bracket from bending and deforming due to the weight of the main unit.

[0119] As shown in FIG. 3, in the vehicle headlamp 1 of the present disclosure, the plurality of convex supported portions extend substantially parallel to one another.

[0120] In this way, by having the multiple convex supported portions extend approximately parallel to one another, it is possible to prevent the convex supported portions of the first bracket from being flexed and deformed due to the weight of the main unit itself.

[0121] Furthermore, as shown in FIG. 3 , in the vehicle headlamp 1 of the present disclosure, the main unit M further has a second bracket B2, and the second bracket B2 has at least one swivel bracket portion (the above-described swivel fixing portion 28 in the present disclosure) that supports the optical unit rotatably around a vertical axis, and a leveling bracket portion (the above-described leveling support portion 29A in the present disclosure) that supports the optical unit rotatably around a horizontal axis, and the swivel unit 20 is fixed to the swivel bracket portion, and the leveling unit 30 is fixed to the leveling bracket portion.

[0122] This makes it possible for the planar supporting portion to prevent the convex supported portion of the first bracket from being bent and deformed due to the weight of the main unit itself.

[0123] As shown in FIG. 3, in the vehicle headlamp 1 of the present disclosure, the leveling unit 30 is fixed to the leveling bracket portion by a leveling shaft (the second spline shaft of the present disclosure described above).

[0124] This allows the leveling unit 30 to be fixed in the horizontal direction while being rotatable about a horizontal axis.

[0125] As shown in FIG. 3, in the vehicle headlamp 1 of the present disclosure, the swivel unit 20 is fixed to the swivel bracket portion by a swivel shaft (the first spline shaft S1 of the present disclosure described above).

[0126] This allows the leveling unit 30 to be fixed in the vertical direction while being rotatable about the vertical axis.

[0127] Furthermore, as shown in Figures 2 and 3, in the vehicle headlamp 1 of the present disclosure, the first bracket B1 has beam portions (the left beam portion 12L and the right beam portion 12R in the present disclosure described above) stretched between the plurality of convex supported portions, and the planar support portion 110S and the beam portions are in surface contact with each other.

[0128] This makes it possible for the planar supporting portion to prevent the convex supported portion of the first bracket from being bent and deformed due to the weight of the main unit itself.

[0129] As shown in FIGS. 2 and 3, in the vehicle headlamp 1 of the present disclosure, the planar support portion 110S and the beam portion are in surface contact with each other.

[0130] This makes it possible for the planar supporting portion to prevent the convex supported portion of the first bracket from being bent and deformed due to the weight of the main unit itself.

[0131] As shown in FIGS. 2 and 3, in the vehicle headlamp 1 of the present disclosure, the beam portion and the planar support portion 110S form a substantially hollow circular shape in a cross section intersecting the stretched direction of the beam portion.

[0132] In this way, the semi-monocoque structure in which the beam portion and the planar support portion form a substantially hollow circular shape can prevent the convex supported portion of the bracket from being flexed and deformed.

[0133] Furthermore, the vehicle headlamp 1 has a lamp unit 10 and a leveling unit 30, and the leveling unit 30 has a drive unit (the first motor MO in the present disclosure described above) that rotates the lamp unit 10 around the leveling axis L2, and when the drive unit is in a non-driven state, a rotational force acts on the lamp unit 10 in a predetermined direction due to the weight of the lamp unit 10.

[0134] This ensures that a rotational force is always applied to the lamp unit in a predetermined direction, eliminating any wobble and improving the accuracy of aiming and leveling.

[0135] In addition, in the vehicle headlamp 1 of the present disclosure as shown in FIGS. 1 to 3, the rotatable angle range of the lamp unit 10 is smaller than ±5° from the horizontal direction around the leveling axis L2.

[0136] As a result, the rotation angle of the lamp unit does not rotate to a direction perpendicular to the leveling axis, so a force is always applied to the lamp unit to rotate it in a predetermined direction, eliminating any rattle and improving the accuracy of aiming and leveling.

[0137] In addition, as shown in FIGS. 1 to 3, in the vehicle headlamp 1 of the present disclosure, the lamp unit 10 is supported so as to be rotatable about the leveling axis L2.

[0138] This ensures that the lamp unit is always rotated in a predetermined direction, eliminating any wobble and improving the accuracy of aiming and leveling.

[0139] Furthermore, as shown in FIG. 4, in the vehicle headlamp 1 of the present disclosure, the leveling unit has a reducer, and the posture of the lamp unit is maintained by frictional force between multiple gears in the reducer against the rotational force.

[0140] As a result, a force is constantly acting on the lamp unit to rotate it in a predetermined direction, but the frictional force of the gears in the reducer allows the orientation of the optical unit to be maintained.

[0141] Furthermore, as shown in FIG. 4, in the vehicle headlamp 1 of the present disclosure, the drive unit and the plurality of gears are connected together without play within the movable range of the optical axis of the lamp unit.

[0142] As a result, a force is always acting on the lamp unit to rotate it in a predetermined direction, but the drive unit and multiple gears are connected without any play, so the orientation of the optical unit can be maintained.

[0143] As shown in Figures 3 to 8, the vehicle headlamp 1 of the present disclosure includes an attachment portion (first output gear TO1) having a resilient coupling portion and a hollow support portion including a substantially cylindrical hollow portion extending in the direction of the leveling axis L2, and an approximately cylindrical spline shaft (the second spline shaft S2 in the present disclosure described above) having an resilient coupling portion, and when the spline shaft is inserted into the hollow portion, the resilient coupling portion is resiliently coupled to the resilient coupling portion, and the lamp unit is assembled to the attachment portion in a state where it is supported by the hollow support portion via the spline shaft.

[0144] This allows the spline shaft to be easily assembled and disassembled using a snap-fit ​​structure.

[0145] Furthermore, as shown in Figures 3 to 8, in the vehicle headlamp 1 of the present disclosure, at least one tongue portion (the first mounting tongue portion FT1 in the present disclosure described above) that is elastically deformable in the radial direction is provided at the tip of the spline shaft in the insertion direction, and the elastically coupled portion has at least one window portion W that is elastically deformable in the radial direction at a position that corresponds to the tongue portion when the spline shaft is assembled to the bracket, and when the spline shaft is inserted into the hollow portion, the tongue portion is elastically fitted into the window portion.

[0146] This allows the spline shaft to be easily assembled and disassembled using a snap-fit ​​structure.

[0147] <Second embodiment> In the above-described first embodiment, a configuration has been described in which the first bracket B1 is fixed to the housing 100, the swivel unit 20 enables the second bracket B2, the leveling unit 30, and the lamp unit 10 to rotate about the swivel axis L1 relative to the first bracket B1, and the leveling unit 30 enables the lamp unit 10 to rotate about the leveling axis L2 relative to the second bracket B2. However, the present disclosure is not limited to this.

[0148] Fig. 14 is a perspective view of a vehicle headlamp 1' according to the second embodiment. As shown in Fig. 14, the vehicle headlamp 1' includes a third bracket B3 fixed to a housing (not shown), a leveling unit 30 that rotates relative to the third bracket B3 about a main leveling axis ML2, a fourth bracket B4 fixed to the leveling unit 30, and three subunits S (SM, SL, SR) that are supported rotatably relative to the fourth bracket B4 about swivel axes ML1, LL1, and RL1, respectively.

[0149] In the illustrated example, the subunits S include a left subunit SL located on the far left, a right subunit SR located on the far right, and a central subunit SM located between the left subunit SL and the right subunit SR.

[0150] The central subunit SM can rotate around the central swivel axis ML1 relative to the fourth bracket B4 by the swivel unit 20. The connection structure between the swivel unit 20 and the fourth bracket B4 is similar to the connection structure between the swivel unit 20 and the first bracket B1 in the first embodiment described above. Furthermore, the structure of the swivel unit 20 of this embodiment, including the motor and multiple gears, is similar to that of the swivel unit 20 of the first embodiment.

[0151] In this way, the central subunit SM is provided with a swivel unit 20 that rotates the lamp unit 10 of the central subunit SM about the central swivel axis ML1, but the left subunit SL and the right subunit SR are not provided with a swivel unit 20. The rotation of the swivel unit 20 of the central subunit SM is transmitted to the left subunit SL and the right subunit SR via a link unit LU provided on the fourth bracket B4.

[0152] The link unit LU (rotational support part) has a central link bracket MLB provided on the central subunit SM, a left link bracket LLB provided on the left subunit SL, a right link bracket RLB provided on the right subunit SR, a left arm LA suspended between the central link bracket MLB and the left link bracket LLB, a right arm RA suspended between the central link bracket MLB and the right link bracket RLB, a left connecting part LC that rotatably connects the left arm LA and the left link bracket LLB, a right connecting part RC that rotatably connects the right arm RA and the right link bracket RLB, and a central connecting part MC that rotatably connects the left arm LA, the right arm RA, and the central link bracket MLB. When the central link bracket MLB rotates about the central swivel axis ML1, the displacement of the central link bracket MLB is transmitted to the left arm LA and the right arm RA, causing the left link bracket LLB and the right link bracket RLB to rotate about the left swivel axis LL1 and the right swivel axis RL1, respectively.

[0153] The link unit LU makes the amount of rotation of the center subunit SM about the center swivel axis, the amount of rotation of the left subunit SL about the left swivel axis, and the amount of rotation of the right subunit SR about the right swivel axis equal.

[0154] Figures 15 and 16 are schematic diagrams of the left subunit SL. Figure 15 is a side view of the left subunit SL, and Figure 16 is a cross-sectional view of the left subunit SL shown in Figure 15 taken along line XVI-XVI. As shown in Figures 15 and 16, the left subunit SL includes a left lamp unit 10L, a third spline shaft S3, a fixed cylinder portion FC, a left lamp bracket 14L to which the left lamp unit 10L is fixed, a left link bracket LLB, a left pre-aiming unit 30L, a left phase adjustment unit PU, and a left vibration suppression unit BU.

[0155] The third spline shaft S3 passes through the fourth bracket B4 and the left link bracket LLB and is fixed to the fixed cylinder portion FC. The window portion W of the output gear in the first embodiment is provided in the fixed cylinder portion FC of this embodiment, and the locking claw 23L of the third spline shaft S3 fits into the fixed cylinder portion FC. A left ramp bracket 14L and a left link bracket LLB are provided on the outer periphery of the fixed cylinder portion FC so as to be rotatable about the left swivel axis LL1. The left ramp bracket 14L and the left link bracket LLB slide along the outer periphery of the fixed cylinder portion FC.

[0156] The left pre-aiming unit 30L is provided on the left lamp bracket 14L. The left pre-aiming unit 30L supports the left lamp unit 10L relative to the left lamp bracket 14L so that the left lamp unit 10L can rotate about a left pre-aiming axis AA that is parallel to the main leveling axis ML2 (see FIG. 16 ). When the left pre-aiming unit 30L is activated, the left lamp unit 10L rotates about the left pre-aiming axis AA. The left pre-aiming unit 30L can adjust the vertical posture of the left lamp unit 10L more precisely than the leveling unit 30.

[0157] The left phase adjustment unit PU connects the left lamp bracket 14L and the left link bracket LLB. The left phase adjustment unit PU transmits the rotation of the left link bracket LLB about the left swivel axis LL1 to the left lamp bracket 14L. When the left link bracket LLB rotates about the left swivel axis LL1 via the link unit LU, the left lamp bracket 14L rotates about the left swivel axis LL1 via the left phase adjustment unit PU. The left phase adjustment unit PU can change the amount of advance angle between the left lamp unit 10L and the left link bracket LLB about the left swivel axis LL1. The advance angle is an amount (angle) that indicates how many degrees the left lamp unit 10L advances from a reference angle about the left swivel axis LL1 relative to the left link bracket LLB.

[0158] The left vibration suppression unit BU prevents rattle from occurring between the left link bracket LLB and the left lamp bracket 14L. The left vibration suppression unit BU continuously applies a force to the left lamp bracket 14L to rotate it in one direction about the left swivel axis LL1. This makes it less likely that a gap will occur between the left link bracket LLB and the left lamp bracket 14L, and reduces the likelihood of abnormal noise being generated when vibrations act on the vehicle headlamp 1'.

[0159] In this way, when the swivel unit 20 is activated, the central lamp unit 10M rotates around the central swivel axis ML1, the left lamp unit 10L rotates around the left swivel axis LL1 via the link unit LU, and the right lamp unit 10R rotates around the right swivel axis RL1 via the link unit LU.

[0160] Furthermore, when the leveling unit 30 is actuated, the third bracket B3 rotates about the leveling axis L2 relative to the housing 100. The third bracket B3 is provided with a central lamp unit 10M, a left lamp unit 10L, and a right lamp unit 10R. Therefore, when the leveling unit 30 is actuated, the central lamp unit 10M, the left lamp unit 10L, and the right lamp unit 10R rotate all at once.

[0161] The vehicle headlamp 1' according to the second embodiment described above also includes the lamp unit 10 in the right subunit SR, the leveling unit 30 fixed to the lamp unit 10, and a fourth bracket (bracket) B4 that rotatably supports the lamp unit 10 and the leveling unit 30. With this configuration, the angle at which the leveling unit 30 rotates matches the angle at which the lamp unit 10 rotates. Therefore, as with the first embodiment, the vehicle headlamp 1' according to the second embodiment is easy to design because it does not need to be designed differently for each vehicle model in order to adjust the optical axis of the lamp unit 10 in the up-down direction.

[0162] Furthermore, the vehicle headlamp 1' of the present disclosure has a housing 100 and a main unit M, the main unit M having a leveling unit 30, at least one swivel unit 20, at least one optical unit, and a first bracket (the third bracket B3 in the present disclosure described above), and the main unit M is attached to the housing 100 by the first bracket.

[0163] Therefore, similarly to the first embodiment, the vehicle headlamp 1' according to the second embodiment can also be provided as a vehicle headlamp 1' that is easy to assemble and does not require waterproofing components.

[0164] As shown in FIG. 14 , in the vehicle headlamp 1′ of the present disclosure, the first bracket has at least three convex supported portions (111U, 111R, 111L), and the housing 100 has at least three convex supporting portions that protrude toward the first bracket and each support the convex supported portion, and a planar supporting portion that connects the multiple convex supporting portions to each other.

[0165] Furthermore, in the vehicle headlamp 1 ′ of the present disclosure, the main unit M is fixed to the housing 100 by inserting the plurality of convex supporting portions into the plurality of convex supported portions, respectively.

[0166] Furthermore, as shown in Figure 14, in the vehicle headlamp 1' of the present disclosure, the multiple convex supported portions include upper convex supported portions (upper mounting portion 111U in the present disclosure described above) and lower convex supported portions (left mounting portion 111L and right mounting portion 111R in the present disclosure described above) located below the upper convex supported portions.

[0167] As shown in FIG. 3, in the vehicle headlamp 1' of the present disclosure, the plurality of convex supported portions extend substantially parallel to one another.

[0168] Furthermore, as shown in FIG. 3, in the vehicle headlamp 1′ of the present disclosure, the main unit M further has a second bracket (the fourth bracket B4 in the present disclosure described above), and the second bracket has at least one plate-shaped swivel bracket portion extending in the front-to-rear and left-to-right directions, and a plate-shaped leveling bracket portion connected to the swivel bracket portion and extending in the up-down direction, and the swivel unit 20 is fixed to the swivel bracket portion, and the leveling unit 30 is fixed to the leveling bracket portion.

[0169] In the vehicle headlamp 1' of the present disclosure, the leveling unit 30 is fixed to the leveling bracket portion by a leveling shaft.

[0170] In the vehicle headlamp 1' of the present disclosure, the swivel unit 20 is fixed to the swivel bracket portion by a swivel shaft.

[0171] Furthermore, the vehicle headlamp 1' of the present disclosure has a lamp unit 10 and a leveling unit 30, and the leveling unit 30 has a drive unit that rotates the lamp unit 10 around a leveling axis L2, and when the drive unit is in a non-driven state, a rotational force acts on the lamp unit around the leveling axis due to the lamp unit's own weight.

[0172] Therefore, as in the first embodiment, in the vehicle headlamp 1' according to the second embodiment, a rotational force is always acting on the lamp unit in a predetermined direction, eliminating any rattle and improving the accuracy of aiming and leveling.

[0173] As described above, this specification discloses the following: (1) A vehicle headlamp comprising: a lamp unit, a leveling unit fixed to the lamp unit, and a bracket that rotatably supports the lamp unit and the leveling unit.

[0174] (2) The vehicle headlamp according to item (1), wherein the leveling unit has a fixed portion fixed to the bracket and a rotating portion that rotates around a leveling axis relative to the fixed portion, and the rotating portion is fixed to the lamp unit.

[0175] (3) The vehicle headlamp according to item (2), wherein the fixed portion is a shaft member extending along the leveling axis, and the rotating portion includes a motor that rotates the rotating portion relative to the fixed portion.

[0176] (4) The vehicle headlamp according to item (2), wherein the fixed portion includes a motor that rotates the rotating portion relative to the fixed portion, and the rotating portion is a shaft member that extends along the leveling axis.

[0177] (5) The vehicle headlamp according to item (3) or (4), wherein the shaft member is a hollow member along the leveling axis.

[0178] (6) The vehicle headlamp according to any one of items (2) to (5), further including a spline shaft that fixes a positional relationship between the fixing portion and the bracket, and the spline shaft is a hollow member.

[0179] (7) The vehicle headlamp according to item (6), wherein the rotating portion is slidably supported on an outer peripheral surface of the fixed portion.

[0180] (8) The vehicle headlamp according to item (7), wherein the fixing portion has an outer diameter of 10 mm or more.

[0181] (9) A vehicle headlamp according to any one of items (1) to (8), wherein one of the lamp unit and the leveling unit includes a plate-shaped member having an insertion hole with a recess formed on its inner circumferential surface, the other of the lamp unit and the leveling unit includes an insertion portion inserted into the insertion hole, and a claw portion capable of penetrating the recess is formed on the outer periphery of the insertion portion, and when the insertion portion is inserted into the insertion hole and the claw portion has penetrated the recess, the lamp unit is rotated relative to the leveling unit along the circumferential direction of the insertion portion, thereby causing the claw portion to engage with the plate-shaped member.

[0182] (10) The vehicle headlamp according to item (9), wherein the plate-shaped member or the insertion portion is provided on a side surface of the lamp unit.

[0183] (11) A vehicle headlamp according to any one of items (1) to (10), wherein a first screw hole is formed in the lamp unit, and a second screw hole is formed in the leveling unit at a position corresponding to the first screw hole when the lamp unit is attached.

[0184] (12) The vehicle headlamp according to any one of items (2) to (8), wherein one of the fixed portion and the rotating portion has a first gear, the other of the fixed portion and the rotating portion has a reducer that meshes with the first gear, and the reducer is provided at a position that overlaps with the one of the members in the extension direction of the leveling axis.

[0185] (13) A vehicle headlamp comprising: a housing; and a main unit; the main unit comprising: a leveling unit; a swivel unit; an optical unit; and a first bracket; the main unit being attached to the housing by the first bracket.

[0186] (14) The vehicle headlamp according to item (13), wherein the first bracket has at least three convex supported portions, and the housing has at least three convex supporting portions that protrude toward the first bracket and each support the convex supported portion, and a planar supporting portion that connects the plurality of convex supporting portions to each other.

[0187] (15) The vehicle headlamp according to item (14), wherein the main unit is fixed to the housing by inserting the plurality of convex supporting portions into the plurality of convex supported portions, respectively.

[0188] (16) The vehicle headlamp according to any one of items (13) to (15), wherein the main unit further has a second bracket, and the second bracket has a swivel bracket portion that supports the optical unit rotatably around a vertical axis, and a leveling bracket portion that supports the optical unit rotatably around a horizontal axis, and the swivel unit is fixed to the swivel bracket portion, and the leveling unit is fixed to the leveling bracket portion.

[0189] (17) The vehicle headlamp according to item (16), wherein the leveling unit is fixed to the leveling bracket portion by a leveling shaft.

[0190] (18) The vehicle headlamp according to item (16), wherein the swivel unit is fixed to the swivel bracket portion by a swivel shaft.

[0191] (19) The vehicle headlamp according to item (14) or (15), wherein the first bracket has a beam portion stretched between the plurality of convex supported portions, and the planar supporting portion and the beam portion are in surface contact with each other.

[0192] (20) The vehicle headlamp according to item (19), wherein the planar support portion and the beam portion are in contact with each other at curved surfaces.

[0193] (21) The vehicle headlamp according to item (19) or (20), wherein the beam portion and the planar support portion have a substantially hollow circular shape in a cross section intersecting the stretched direction of the beam portion.

[0194] (22) A vehicle headlamp comprising: a lamp unit; and a leveling unit, wherein the leveling unit has a drive unit that rotates the lamp unit around a leveling axis, and when the drive unit is in a non-driven state, a rotational force acts on the lamp unit around the leveling axis due to the weight of the lamp unit.

[0195] (23) The vehicle headlamp according to item (22), wherein the rotatable angle range of the lamp unit is less than ±5° from the horizontal direction around the leveling axis.

[0196] (24) The vehicle headlamp according to item (22) or (23), wherein the lamp unit is supported so as to be rotatable around the leveling axis.

[0197] (25) The vehicle headlamp according to any one of items (22) to (24), wherein the leveling unit has a reducer, and the attitude of the lamp unit is maintained by a frictional force between a plurality of gears in the reducer against the rotational force.

[0198] (26) The vehicle headlamp according to item (25), wherein the drive unit and the plurality of gears are connected together without play within a movable range of the optical axis of the lamp unit.

[0199] (27) A vehicle headlamp according to any one of items (22) to (26), comprising: an attachment portion having a resilient coupling portion and a hollow support portion including a substantially cylindrical hollow portion extending in the direction of the leveling axis; and an approximately cylindrical spline shaft having an resilient coupling portion, wherein the spline shaft is inserted into the hollow portion, so that the resilient coupling portion is resiliently coupled to the resilient coupling portion, and the lamp unit is assembled to the attachment portion in a state where it is supported by the hollow support portion via the spline shaft.

[0200] (28) A vehicle headlamp according to item (27), wherein at least one tongue portion elastically deformable in the radial direction is provided at the tip of the spline shaft in the insertion direction, the elastically coupled portion has at least one window portion at a position corresponding to the tongue portion when the spline shaft is assembled to the attachment portion, and the tongue portion is elastically fitted into the groove portion when the spline shaft is inserted into the hollow portion.

[0201] (29) The vehicle headlamp according to any one of items (22) to (28), further comprising a rotation support portion that supports the lamp unit so that the lamp unit can rotate.

[0202] Although the embodiments of the present disclosure have been described above, it goes without saying that the technical scope of the present disclosure should not be interpreted as being limited by the description of the present embodiments. The present embodiments are merely examples, and it will be understood by those skilled in the art that various modifications of the embodiments are possible within the scope of the invention described in the claims. The technical scope of the present disclosure should be determined based on the scope of the invention described in the claims and its equivalents.

[0203] This application is based on Japanese Patent Application No. 2023-222315 filed on December 28, 2023, Japanese Patent Application No. 2023-222317 filed on December 28, 2023, and Japanese Patent Application No. 2023-222320 filed on December 28, 2023, the contents of which are incorporated herein by reference.

Claims

1. A vehicle headlamp comprising a lamp unit, a leveling unit fixed to the lamp unit, and a bracket rotatably supporting the lamp unit and the leveling unit.

2. The vehicle headlamp according to claim 1, wherein the leveling unit has a fixed portion fixed to the bracket and a rotating portion that rotates about a leveling axis with respect to the fixed portion, and the rotating portion is fixed to the lamp unit.

3. The vehicle headlamp according to claim 2, wherein the fixed portion is a shaft member extending along the leveling axis, and the rotating portion includes a motor that rotates the rotating portion with respect to the fixed portion.

4. The vehicle headlamp according to claim 2, wherein the fixed portion includes a motor that rotates the rotating portion with respect to the fixed portion, and the rotating portion is a shaft member extending along the leveling axis.

5. The vehicle headlamp according to claim 3 or claim 4, wherein the shaft member is a hollow member along the leveling axis.

6. The vehicle headlamp according to claim 2, further comprising a spline shaft that fixes the positional relationship between the fixed portion and the bracket, and the spline shaft is a hollow member.

7. The vehicle headlamp according to claim 6, wherein the rotating portion is slidably supported on the outer peripheral surface of the fixed portion.

8. The vehicle headlamp according to claim 7, wherein the outer diameter of the fixed portion is 10 mm or more.

9. One of the lamp unit and the leveling unit includes a plate-like member having an insertion hole with a recess formed in the inner peripheral surface, and the other of the lamp unit and the leveling unit includes an insertion portion inserted into the insertion hole. A claw portion capable of penetrating the recess is formed on the outer periphery of the insertion portion. When the insertion portion is inserted into the insertion hole and the claw portion penetrates the recess, the lamp unit is rotated relative to the leveling unit along the circumferential direction of the insertion portion, so that the claw portion engages with the plate-like member. The vehicle headlamp according to claim 1.

10. The vehicle headlamp according to claim 9, wherein the plate-like member or the insertion portion is provided on the side surface of the lamp unit.

11. The lamp unit has a first screw hole, and the leveling unit has a second screw hole formed at a position corresponding to the first screw hole in a state where the lamp unit is attached. The vehicle headlamp according to claim 1.

12. One of the members of the fixing part and the rotating part has a first gear, the other member of the fixing part and the rotating part has a speed reducer meshing with the first gear, and the speed reducer is provided at a position overlapping with the one member in the extending direction of the leveling axis. The vehicle headlamp according to claim 2.

13. It has a housing and a main unit. The main unit has a leveling unit, a swivel unit, an optical unit, and a first bracket, and the main unit is attached to the housing by the first bracket. The vehicle headlamp.

14. The first bracket has at least three convex supported parts, and the housing has at least three convex supporting parts protruding toward the first bracket and each supporting the convex supported part, and a planar supporting part connecting the plurality of convex supporting parts to each other. The vehicle headlamp according to claim 13.

15. The plurality of convex supporting parts are each inserted into the plurality of convex supported parts, whereby the main unit is fixed to the housing. The vehicle headlamp according to claim 14.

16. The main unit further has a second bracket. The second bracket has a swivel bracket part that rotatably supports the optical unit around a vertical axis and a leveling bracket part that rotatably supports the optical unit around a horizontal axis. The swivel unit is fixed to the swivel bracket part, and the leveling unit is fixed to the leveling bracket part. The vehicle headlamp according to claim 13.

17. The leveling unit is fixed to the leveling bracket part by a leveling shaft. The vehicle headlamp according to claim 16.

18. The swivel unit is fixed to the swivel bracket part by a swivel shaft. The vehicle headlamp according to claim 16.

19. The first bracket has a beam portion spanned between a plurality of the convex supported portions, and the planar support portion and the beam portion are in surface contact with each other. The vehicle headlamp according to claim 14.

20. The vehicle headlamp according to claim 19, wherein the planar support portion and the beam portion are in contact with each other with curved surfaces.

21. In a cross section intersecting the spanning direction of the beam portion, the beam portion and the planar support portion form a substantially hollow circular shape. The vehicle headlamp according to claim 19.

22. A vehicle headlamp having a lamp unit and a leveling unit, the leveling unit having a drive unit for rotating the lamp unit around a leveling axis, and in a non-driven state of the drive unit, a rotational force acts on the lamp unit around the leveling axis due to the self-weight of the lamp unit.

23. The vehicle headlamp according to claim 22, wherein a rotatable angle range of the lamp unit is less than ±5° from the horizontal direction centered on the leveling axis.

24. The vehicle headlamp according to claim 22, wherein the lamp unit is rotatably supported around the leveling axis.

25. The leveling unit has a speed reducer, and the posture of the lamp unit is maintained by frictional forces between a plurality of gears in the speed reducer against the rotational force. The vehicle headlamp according to claim 22.

26. In a movable range of the optical axis of the lamp unit, the drive unit and the plurality of gears are connected without play. The vehicle headlamp according to claim 25.

27. A mounted portion having an elastically coupled portion and a hollow support portion including a substantially cylindrical hollow portion extending in the direction of the leveling axis, and a substantially cylindrical spline shaft having an elastic coupling portion. By inserting the spline shaft into the hollow portion, the elastic coupling portion is elastically coupled to the elastically coupled portion, and the lamp unit is assembled to the mounted portion while being supported by the hollow support portion via the spline shaft. The vehicle headlamp according to claim 22.

28. At least one tongue portion that is elastically deformable in the radial direction is provided at the tip of the spline shaft in the insertion direction, the elastically coupled portion has at least one window portion at a position corresponding to the tongue portion when the spline shaft is assembled to the attached portion, and when the spline shaft is inserted into the hollow portion, the tongue portion is elastically fitted into the groove portion. The vehicle headlamp according to claim 27.

29. The vehicle headlamp according to claim 22, further comprising a rotation support portion that rotatably supports the lamp unit.

Images