Component attachment structure, jig, and vehicle lamp

Abstract

This component attachment structure is used in a vehicle lamp and comprises: an axially extending cylindrical attachment portion (S1) having a plurality of claw portions (23L); and a cylindrical attachment-receiving portion (TO1) into which the attachment portion (S1) is inserted and in which a plurality of radially penetrating window portions are formed, into which window portions the claw portions (23L) enter from the radially inner side. The attachment portion (S1) comprises a body portion (26) and an annular flange portion (22) provided at an end of the body portion (26). The body portion (26) comprises an extension portion (23) extending axially from the flange portion (22) and forming a lateral peripheral surface, and a claw portion (23L) protruding radially outward from the extension portion (23). A hook-shaped portion (25R) for elastically deforming the extension portion (23) so as to draw the claw portion (23L) radially inward is provided so as to protrude radially inward from the extension portion (23).

Description

Component mounting structure, jig, and vehicle lighting fixture

[0001] The present disclosure relates to a component mounting structure, a jig, and a vehicle lamp.

[0002] Patent Document 1 discloses a vehicle lamp equipped with a leveling device.

[0003] Japanese Patent Application Publication No. 9-282908

[0004] In conventional vehicle lamps, in order to remove various components provided in the vehicle lamp, it is necessary to take several steps, such as removing screws.

[0005] An object of the present disclosure is to provide a component mounting structure, a jig, and a vehicle lamp that allow components provided in a vehicle lamp to be easily removed.

[0006] A component mounting structure according to one aspect of the present disclosure comprises: a cylindrical mounting portion extending in the axial direction and having a plurality of claw portions; and a cylindrical mounted portion into which the mounting portion is inserted and which penetrates radially and has a plurality of windows through which the claw portions enter from the inner diameter side, wherein the mounting portion has: an annular flange portion provided at an end; an extension portion extending from the flange in the axial direction to form a side peripheral surface; and the claw portions protruding radially outward from the extension portion, and a hook-shaped portion for elastically deforming the extension portion so as to draw the claw portions radially inward is provided protruding radially inward from the extension portion.

[0007] According to the present disclosure, it is possible to provide a component mounting structure, a jig, and a vehicle lamp that allow components provided in a vehicle lamp to be easily removed.

[0008] FIG. 1 is a schematic diagram of a vehicle headlamp according to an embodiment of the present disclosure. FIG. 2 is a perspective view of a lamp unit, a leveling unit, and a swivel unit. FIG. 3 is an exploded perspective view of a main unit. FIG. 4 is an exploded perspective view of a swivel unit. FIG. 5 is a diagram illustrating an attachment structure of a first bracket, a swivel unit, and a first spline shaft. FIG. 6 is a perspective view of the first spline shaft. FIG. 7 is a cross-sectional view of a first output gear and a first spline shaft taken along a cross section perpendicular to the swivel axis direction. FIG. 8 is a perspective view of a lamp unit and a leveling unit. FIG. 9 is a perspective view of a removal jig used when removing the first spline shaft. FIG. 10 is a view illustrating a step portion according to a modified example. FIG. 11 is a perspective view of a vehicle headlamp according to a second embodiment. FIG. 12 is a side view of a left subunit. FIG. 13 is a cross-sectional view taken along line XIII-XIII in FIG. 12.

[0009] 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.

[0010] <First embodiment> (Overall configuration) Fig. 1 is a schematic 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.

[0011] The extension Sa is provided between the outer lens 200 and the main unit M. The extension Sa is a member that makes it difficult for components inside the lamp chamber and the inner surface of the housing 100 to be seen from the outside through the outer lens 200, thereby improving the aesthetic appearance of the vehicle headlamp 1.

[0012] 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.

[0013] 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.

[0014] 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 , which will be described later). While the illustrated example shows an example in which a single lens L is mounted on the lamp unit 10, multiple lenses or multiple reflectors may be mounted. Furthermore, the lamp unit 10 may be provided with either a single light source 17 or multiple light sources 17.

[0015] 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 .

[0016] 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 each other to form one 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.

[0017] (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.

[0018] (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.

[0019] In the illustrated example, the mounting portion 11 includes 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.

[0020] 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. A through hole 13H penetrating in the up-down direction is formed in the bottom portion 13. A lance structure may 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.

[0021] (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 portion 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 above the bottom 13 of the first bracket B1.

[0022] (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 is an example of a rotating unit that rotates the lamp unit 10 relative to the first bracket B1. The swivel unit 20 engages with the first spline shaft S1 above the bottom 13 of the first bracket B1.

[0023] 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.

[0024] 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.

[0025] 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 of the first motor MO transmits torque to the first reduction gear unit D. The first reduction gear unit D includes 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 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.

[0026] 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.

[0027] 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.

[0028] (Axial Fixation) FIG. 5 is a diagram illustrating the mounting structure of the first bracket B1, the swivel unit 20, and the first spline shaft S1. The mounting structure according to the present disclosure refers to a structure in which the first spline shaft S1 (mounting portion) and the first output gear TO1 (mounted portion) are engaged with each other. In the following description, the first spline shaft S1 may also be referred to as the mounting portion S1, and the first output gear TO1 may also be referred to as the mounted portion TO1. FIG. 5 illustrates a cross section of the first bracket B1, the swivel unit 20, and the first spline shaft S1 taken along the swivel axis L1. The first output gear TO1 is disposed inside the first casing 21 so as to be rotatable about the swivel axis L1 but immovable in the swivel axis L1 direction. As shown in FIG. 4, the first output gear TO1 is a hollow member into which the first spline shaft S1 can be inserted. A radially penetrating window W is formed in a portion of the outer circumferential surface of the first output gear TO1.

[0029] 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 an extension 23 extending from the flange 22 along the swivel axis L1. A claw 23L is provided at the axial tip of the extension 23. The extension 23 is an elongated portion in the axial direction, and the tip is elastically deformable in the radial direction.

[0030] Returning to Figure 5, the engagement between the first spline shaft S1 (mounting portion) and the first output gear TO1 (mounted portion) will be described. With the first output gear TO1 and the through hole 13H provided in the bottom portion 13 of the first bracket B1 positioned coaxially, the first spline shaft S1 is inserted into the first output gear TO1 so as to pass through the through hole 13H of the first bracket B1. Therefore, the swivel unit 20 and the flange portion 22 of the first spline shaft S1 are positioned so as to sandwich the bottom portion 13 of the first bracket B1.

[0031] When the first spline shaft S1 is inserted into the first output gear TO1, the tip of the extension 23 in the insertion direction is pressed against the inner circumferential surface of the first output gear TO1 and elastically deforms radially inward. When the first spline shaft S1 is further inserted into the first output gear TO1, the claws 23L fit into the windows W of the first output gear TO1, as shown in Figure 5, and the elastic deformation of the extension 23 radially inward is released. With the claws 23L fitted into the windows W in this manner, the claws 23L are in contact with the windows W, and the first spline shaft S1 cannot move in the direction of the swivel axis L1.

[0032] As shown in Figure 5, a hook-shaped portion 25R is provided on the inner peripheral surface of the extension portion 23. In the cross section shown, the hook-shaped portion 25R has a hook-like shape that protrudes radially inward from the inner peripheral surface of the extension portion 23 and then bends back toward the flange portion 22. The hook-shaped portion 25R can be displaced so as to be pulled radially inward, thereby elastically deforming the entire extension portion 23 radially inward. Furthermore, the inner peripheral surface of the tip of the hook-shaped barb is an inclined surface that increases in diameter as it moves away from the flange portion 22 in the axial direction.

[0033] 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 22 in the direction of the swivel axis L1. The 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.

[0034] Each first mounting tongue FT1 has an extension portion 23 with a claw portion 23L at its tip, an abutment portion 24, and an insertion guide portion 25. A pair of abutment portions 24 are provided on both circumferential sides of the extension portion 23, sandwiching the extension portion 23. The abutment portions 24 extend from the flange portion 22 to a length greater than the extension portion 23. The pair of abutment portions 24 extend at an angle so that the distance between them becomes narrower as they move away from the flange portion 22. The ends of the abutment portions 24 opposite the flange portion 22 are connected in the circumferential direction by the insertion guide portion 25. The claw portion 23L at the tip of the extension portion 23 is not connected to the insertion guide portion 25. The outer peripheral surface of the insertion guide portion 25 opposite the flange portion 22 has a conical shape whose outer diameter decreases as it moves away from the flange portion 22. In the illustrated example, pairs of abutment portions 24 are provided at three locations spaced apart in the circumferential direction of the first spline shaft S1.

[0035] 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 an auxiliary support 27 that is provided at the tip of the main body 26. Similar to the insertion guide 25, the outer peripheral surface of the auxiliary support 27 has a conical shape whose outer diameter decreases with increasing distance from the flange 22.

[0036] 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 claws 23L engage with the window portions W of the first bracket B1. Because the claws 23L contact the wall surfaces of the window portions W, relative rotation between the first spline shaft S1 and the first output gear TO1 about the swivel axis L1 is prevented.

[0037] 7, the through hole TOH of the output gear TO1 is not circular in cross section, and the first bracket B1 has a plurality of protrusions P that protrude radially inward. The first mounting tongues FT1 of the first spline shaft S1 fit between the protrusions P in the circumferential direction. Conversely, the protrusions P of the output gear TO1 fit between the plurality of first mounting tongues FT1 of the first spline shaft S1 in the circumferential direction. The abutment portions 24 of the first spline shaft S1 abut against the protrusions P. This prevents relative rotation between the first spline shaft S1 and the first output gear TO1 about the swivel axis L1.

[0038] 6, the pair of 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 abutment portions 24 are pressed against the protrusion P increases, making it less likely that backlash will occur in the circumferential direction between the first spline shaft S1 and the first output gear TO1.

[0039] Returning to FIG. 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 claws 23L, insertion guide 25, and auxiliary support 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 on the second mounting tongue FT2, the claws 23L, insertion guide 25, and auxiliary support 27 of the first mounting tongue FT1, tending to displace 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 circumferential surface of the insertion hole of the output gear radially outward, reducing the likelihood of radial play between the first spline shaft S1 and the first output gear TO1.

[0040] 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.

[0041] 5 to 7 , the component mounting structure according to the present disclosure includes a cylindrical mounting portion S1 extending in the axial direction and having a plurality of claw portions 23L, and a cylindrical mounted portion TO1 having a plurality of windows W formed therein through which the mounting portion S1 is inserted and through which the claw portions 23L enter from the inner diameter side. The mounting portion S1 includes an annular flange portion 22 provided at an end, an extension portion 23 extending axially from the flange portion 22 to form a side circumferential surface, and claw portions 23L protruding radially outward from the extension portion 23. Hook-shaped portions 25R are provided to protrude radially inward from the extension portion 23 for elastically deforming the extension portion 23 so as to draw the claw portions 23L radially inward.

[0042] For this reason, in the component mounting structure according to the present disclosure, when the mounting portion S1 is inserted into the mounting target portion TO1, the claw portions 23L elastically deform toward the inside of the main body portion 26. Then, when the mounting portion S1 is inserted a predetermined distance in the axial direction into the cylindrical mounting target portion TO1, an elastic restoring force acts on the claw portions 23L, causing the claw portions 23L to engage with the window portions W of the mounting target portion TO1, and the mounting portion S1 and the mounting target portion TO1 are fixed together.

[0043] According to the above structure, the mounting portion S1 and the mounted portion TO1 can be fixed in the axial direction simply by inserting the mounting portion S1 into the mounted portion TO1. This makes it possible to provide a component mounting structure that makes it easy to remove components mounted on a vehicle lamp.

[0044] 6 and 7 , according to the component mounting structure of the present disclosure, the mounting portion S1 may have a pair of abutment portions 24 extending in the axial direction. The mounted portion TO1 may have a stepped portion P protruding radially outward, which can fix the mounting portion S1 in the circumferential direction by engaging with the abutment portions 24. This makes it possible to fix the mounting portion S1 in the circumferential direction of the mounted portion TO1.

[0045] 6 , according to the component mounting structure of the present disclosure, the pair of abutment portions 24 may be connected at the axial ends of the mounting portion S1 and may be provided so as to surround the claw portions 23L. With the above configuration, the pair of abutment portions 24 are connected at the axial ends, which increases the strength of the abutment portions 24. Furthermore, since the claw portions 23L are provided so as to be surrounded by the abutment portions 24, the mounting portion S1 can be formed more compactly than if the claw portions 23L were provided outside the abutment portions 24.

[0046] Furthermore, according to the component mounting structure of the present disclosure, as shown in FIG. 6 , the distance between the pair of abutment portions 24 may decrease in the direction of insertion of the mounting portion S1. According to the above configuration, the pair of abutment portions 24 are formed so as to decrease in size in the direction of insertion of the mounting portion S1, so that when the mounting portion S1 is inserted into the mounting portion TO1, the abutment portions 24 are guided by the mounting portion TO1 and smoothly inserted. Furthermore, when the mounting portion S1 is coupled to the mounting portion TO1 in a state in which a compressive force acts in the axial direction due to the engagement between the claw portion 23L and the window portion W, the pair of abutment portions 24 generate a reaction force in the mounting portion S1 against the mounting portion TO1 that resists this compressive force. This makes it possible to provide a component mounting structure that is less likely to cause rattle between the mounting portion S1 and the mounting portion TO1.

[0047] 6 , in the component mounting structure according to the present disclosure, the mounting portion S1 may have a plurality of auxiliary support portions 27 that connect adjacent pairs of abutment portions 24 in the circumferential direction. The auxiliary support portions 27 may be connected at their axial ends. With the above configuration, the auxiliary support portions 27 connect adjacent abutment portions 24, and the auxiliary support portions 27 are connected at their axial ends, thereby increasing the strength of the abutment portions 24.

[0048] 6, the component mounting structure according to the present disclosure may also include auxiliary support portion 27 provided radially inward of abutment portion 24. With the above configuration, auxiliary support portion 27 is provided radially inward of abutment portion 24, and therefore does not impede the prevention of rotation of abutment portion 24 in the circumferential direction.

[0049] (Separation of Spline Shaft) Next, separation of the first spline shaft S1 (mounting portion S1) in the component mounting structure according to the present disclosure will be described in detail with reference to Fig. 9. Fig. 9 is a perspective view of a removal jig SJ used when removing the first spline shaft S1 (mounting portion S1) from the first output gear TO1 (mounted portion TO1).

[0050] As shown in FIG. 9 , the removal jig SJ has a cylindrical base portion SJB and a cylindrical insertion portion SJI having a smaller diameter than 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 multiple 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 when viewed axially. The curvature of the radial outer diameter (outer peripheral surface) of the removal tongue portions SJT matches the curvature of the claw portions 23L provided on the first spline shaft S1. The inner diameter of the removal tongue portions SJT decreases in the clockwise direction. Here, the curvature of the inner diameter (inner peripheral surface) of the removal tongue portions SJT is at least equal to or greater than the curvature of the inner peripheral surface of the claw portions and gradually changes circumferentially. A rotation stopper SJS is provided at the clockwise tip of the removal tongue SJT, protruding radially outward from the outer circumferential surface.

[0051] 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 now 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 extension portion 23 of the first spline shaft S1 abuts against the rotation stopper SJS. As the removal jig SJ is rotated counterclockwise, the side surface of the removal tongue portion SJT comes into contact with the wall surface of the hook 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 hook portion 25R radially inward. When the hook portion 25R is pulled radially inward, the first mounting tongue portion FT1 of the first spline shaft S1 is displaced radially inward in the axial direction L1 away from the flange portion 22, and the claw portion 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.

[0052] The removal jig according to the present disclosure has the above structure, and by inserting the removal jig into the component mounting structure and rotating it, the components can be easily released from their engaged state, which not only makes it easier to replace the components but also makes it easier to recycle the vehicle lamp when it is discarded.

[0053] 5, the mounting portion S1 is provided with hook-shaped portions 25R that protrude radially inward from the extension portion 23. The hook-shaped portions 25R elastically deform so as to retract the claw portions 23L provided on the extension portion 23 radially inward. The cylindrical mounting portion TO1 has an open internal space, so that inserting a tool into this space causes the hook-shaped portions 25R of the mounting portion S1 to deform so as to retract radially inward, thereby easily releasing the engagement between the claw portions 23L of the mounting portion S1 and the window portion W of the mounting portion TO1. This provides a mounting structure for a vehicle lamp that allows for easy removal of the device.

[0054] Furthermore, the shape of the step portion P of the output gear TO1 against which the abutment portion 24 of the first spline shaft S1 abuts is not limited to the above-described example. FIG. 10 is a diagram showing a modified example of a step portion P'. As shown in FIG. 10, a recess P1' may be provided on the side opposite to the surface that contacts the abutment portion 24 so that the step portion P' can elastically deform when it contacts the abutment portion 24. With this configuration, when the abutment portion 24 and the step portion P' contact each other, an elastic restoring force acts on the step portion P' toward the abutment portion 24. This makes it less likely that a circumferential gap will occur between the first spline shaft S1 and the output gear TO1. The recess P1' does not have to be formed in all step portions as shown in FIG. 10. For example, a recess P1' may be provided in at least one step portion.

[0055] (Second Bracket B2) Returning to FIG. 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 leveling unit 30 is an example of a rotating unit that rotates the lamp unit 10 relative to the second bracket B2. 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.

[0056] 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.

[0057] A fitting hole 28H penetrating in the vertical direction is formed in the swivel fixing portion 28 of the second bracket B2. The fitting hole 28H fits into a fitting portion 20L provided on the upper surface of the first casing 21 of the swivel unit 20, and is formed so that the second bracket B2 and the swivel unit 20 can be fixed together.

[0058] The leveling support portion 29A of the second bracket B2 is formed with a support hole 29H penetrating in the left-right direction, and extending along the leveling axis L2.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] 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 support the second bracket B2 without wobbling about the swivel axis L1.

[0063] (Fixing Structure of Lamp Unit 10 and Leveling Unit 30) Fig. 8 is a perspective view showing the lamp unit 10 and the leveling unit 30. As shown in Fig. 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 illustrated example, the lamp bracket 14 is made of metal and has fins that function as a heat sink. The lens holder 15 is attached to the front of the lamp bracket 14. The lens holder 15 supports the projection lens 16.

[0064] 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 on its inner circumferential surface. The second casing 31 of the leveling unit 30 has an insertion portion 31A that is inserted into the fitting hole 14D. The insertion portion 31A has an insertion portion (claw portion) 31B formed on its outer periphery that can pass through the recess 14C. The fitting hole 14D is formed coaxially with the leveling axis L2.

[0065] 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. As a result, the fitting portion 31B fits into the leveling support plate portion 14B.

[0066] 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 formed in the tip surface of the boss 14F. A screw mounting portion 31D in which a screw hole (second screw hole) 31C is formed is also provided in the second casing 31 of the leveling unit 30. A screw that passes through the screw mounting portion 31D of the leveling unit 30 is screwed into the boss 14F of the leveling support plate 14B, thereby fixing the leveling unit 30 and the lamp unit 10 together.

[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 is 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 is 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 headlamps 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] Unlike the vehicle headlamp 1 of the present disclosure, 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 instantaneously. However, according to the vehicle headlamp 1 of the present disclosure, the swivel unit 20 and the leveling unit 30 are driven by a motor M. Therefore, the optical axis of the lamp unit 10 can be moved more quickly than when a screw is used to rotate the lamp unit 10 about the swivel axis L1 or the leveling axis L2.

[0072] Unlike the vehicle headlamp 1 of the present disclosure, an aiming unit is used to align the optical axis of the vehicle headlamp 1 before shipping. However, according to the vehicle headlamp 1 of the present disclosure, the initial position of the motor M can be set as part of the aiming process, 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 is directly grasped by the six-axis sensor and the gyro sensor. The six-axis sensor and the 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. When the six-axis sensor and the gyro sensor are mounted on the leveling unit 30, they may be mounted on the circuit board CR. When the six-axis sensor and the gyro sensor are mounted on the circuit board CR, the sensor can be easily fixed and powered on the circuit board.

[0074] 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 support the second bracket B2 without wobbling about the swivel axis L1.

[0075] Second Embodiment In the first embodiment described above, 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 relative to the first bracket B1 around the swivel axis L1. The leveling unit 30 enables the lamp unit 10 to rotate relative to the second bracket B2 around the leveling axis L2. However, the present disclosure is not limited to this.

[0076] Fig. 11 is a perspective view of a vehicle headlamp 1' according to the second embodiment. As shown in Fig. 11, 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.

[0077] 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.

[0078] 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.

[0079] 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. 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.

[0080] The link unit LU 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 center link bracket MLB rotates about the center swivel axis ML1, the displacement of the center 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. 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.

[0081] The component mounting structure according to the present disclosure is also effective for the multi-lens lamp unit described above. For example, the component mounting structure according to the present disclosure is used in the connection structure between the swivel unit 20 and the fourth bracket B4. This allows multiple swivel units 20 to be efficiently removed.

[0082] The component mounting structure according to the present disclosure may also be used to fasten the left and right subunits S in a multi-lens lamp unit. In the following description, the fastening of the left subunit SL using the component mounting structure according to the present disclosure will be described in detail.

[0083] Figures 12 and 13 are schematic diagrams of the left subunit SL. Figure 12 is a side view of the left subunit SL, and Figure 13 is a cross-sectional view of the left subunit SL taken along line XIV-XIV in Figure 12. As shown in Figures 12 and 13, 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.

[0084] The third spline shaft S3 in this embodiment corresponds to the mounting portion S1 in the first embodiment. 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 formed in the fixed cylinder portion FC of this embodiment, and the claw portion 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.

[0085] 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. 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 finely than the leveling unit 30.

[0086] 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 rotational force of the left link bracket LLB about the left swivel axis LL1 to the left lamp unit 10L. When the left link bracket LLB rotates about the left swivel axis LL1 by 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.

[0087] The left vibration suppression unit BU reduces the likelihood of rattle 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 reduces the likelihood of a gap occurring between the left link bracket LLB and the left lamp bracket 14L, reducing the likelihood of abnormal noise when vibrations act on the vehicle headlamp 1'.

[0088] 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.

[0089] Furthermore, when the leveling unit 30 is activated, 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 activated, the central lamp unit 10M, the left lamp unit 10L, and the right lamp unit 10R rotate all at once.

[0090] The component mounting structure according to the present disclosure may also be employed in the connection between the leveling unit 30 and the third bracket B3 described above.

[0091] 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.

[0092] This application claims priority based on Japanese Patent Application No. 2024-030289 filed on February 29, 2024, and incorporates all of the contents of said application by reference.

Claims

1. A component mounting structure for use in a vehicle lamp, comprising: a cylindrical mounting portion extending in an axial direction and having a plurality of claw portions; and a cylindrical mounted portion into which the mounting portion is inserted and which penetrates radially and has a plurality of windows through which the claw portions enter from the inner diameter side, wherein the mounting portion has: an annular flange portion provided at an end; an extension portion extending from the flange in the axial direction to form a side peripheral surface; and the claw portions protruding radially outward from the extension portion, and a hook-shaped portion for elastically deforming the extension portion so as to draw the claw portions radially inward is provided so as to protrude radially inward from the extension portion.

2. A component mounting structure as described in claim 1, wherein the mounting portion has a plurality of pairs of abutment portions extending in the axial direction, and the mounted portion has stepped portions protruding radially outward that can fix the mounting portion in the circumferential direction by engaging with the abutment portions.

3. A component mounting structure according to claim 2, wherein the pair of abutment portions are connected at the ends in the axial direction, and the pair of abutment portions are provided so as to surround the claw portion.

4. A component mounting structure according to claim 3, wherein the distance between the pair of abutting portions is configured to decrease in the direction in which the mounting portion is inserted.

5. A component mounting structure as set forth in claim 2 or 3, wherein the mounting portion has a plurality of auxiliary support portions that connect adjacent pairs of abutment portions in the circumferential direction, and the plurality of auxiliary support portions are connected at their ends in the axial direction.

6. A component mounting structure according to claim 5, wherein the auxiliary support portion is provided radially inward of the abutment portion.

7. A jig used when removing a mounting portion of a component mounting structure described in any one of claims 1 to 6 from a mounted portion, comprising a cylindrical base portion and an insertion portion having a smaller diameter than said base portion, said insertion portion having a plurality of removal tongue portions extending in the axial direction and curved along the outer periphery of said insertion portion, wherein the curvature of the radial outer peripheral surface of said removal tongue portions matches the curvature of the inner peripheral surface of said claw portions, and the curvature of the radial inner peripheral surface of said removal tongue portions is at least equal to or greater than the curvature of the inner peripheral surface of said claw portions and gradually changes along the circumferential direction.

8. A vehicle lamp having a lamp unit, a bracket, a rotating unit that rotates the lamp unit relative to the bracket, and a shaft that rotatably supports the lamp unit, wherein the bracket and the shaft are fixed by a component mounting structure used in a vehicle lamp according to any one of claims 1 to 6.

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