CN110274210B - Vehicle headlamp - Google Patents

Abstract

The invention aims to provide a vehicle headlamp capable of restraining the enlargement. A vehicle headlamp is provided with: a first light emitting element that emits first light as low beam, a normal line of an emission surface of the first light being directed obliquely downward toward the front; a second light emitting element which is disposed below the first light emitting element and emits second light, a normal line of an emission surface of the second light being directed obliquely upward in the front direction; a light shielding portion extending forward from between the first light emitting element and the second light emitting element; and a projection lens disposed in front of the light shielding portion, through which a part of the first light and a part of the second light directly pass, wherein the light shielding portion has a first reflection surface on an upper surface thereof, which reflects the other part of the first light toward the projection lens, and a second reflection surface on a lower surface thereof, which reflects the other part of the second light toward the projection lens, and a tip of the light shielding portion has a step in a vertical direction corresponding to a shape of a cutoff line of a light distribution pattern of low beams.

Description

Vehicle headlamp

Technical Field

The present invention relates to a vehicle headlamp.

Background

As a vehicle headlamp represented by an automobile headlamp, there is known a vehicle headlamp mounted with a low beam light source for illuminating a front at night and a high beam light source for illuminating a distance farther than the low beam. The light from the high beam light source includes light emitted upward from the low beam. In addition, there is known a vehicle headlamp in which the light source is provided in one lamp unit.

For example, patent document 1 listed below discloses a vehicle lamp including a first light source that emits light upward, a first reflector that is arranged to cover the first light source from above, a second light source that emits light downward, and a second reflector that is arranged to cover the second light source from below. In this vehicle lamp, light emitted from the first light source and reflected by the first reflector and light emitted from the second light source and reflected by the second reflector are irradiated through the projection lens disposed in front of the first light source and the second light source.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open No. 2014-229441

Disclosure of Invention

Problems to be solved by the invention

In the vehicle lamp disclosed in patent document 1, the light emitted from the first light source is emitted upward with respect to the optical axis of the projection lens. In order to allow the light emitted upward to enter the projection lens disposed in front of the first light source, the light emitted from the first light source needs to be reflected forward by the first reflector. Such a first reflector is provided to protrude largely forward to cover the first light source. The second reflector is also arranged to protrude largely forward. However, if the first reflector and the second reflector are increased in size, the vehicle lamp tends to be increased in size.

Accordingly, an object of the present invention is to provide a vehicle headlamp capable of suppressing an increase in size.

Means for solving the problems

In order to solve the above problem, a vehicle headlamp according to the present invention includes: a first light emitting element that emits first light as low beam, a normal line of an emission surface of the first light being directed obliquely downward toward the front; a second light emitting element which is disposed below the first light emitting element and emits second light, a normal line of an emission surface of the second light being directed obliquely upward in the front direction; a light shielding portion extending forward from between the first light emitting element and the second light emitting element; and a projection lens disposed in front of the light shielding portion and directly transmitting a part of the first light and a part of the second light, wherein the light shielding portion has a first reflection surface on an upper surface thereof, which reflects the other part of the first light, so that the other part of the first light transmits through the projection lens, and a second reflection surface on a lower surface thereof, which reflects the other part of the second light, so that the other part of the second light transmits through the projection lens, and a tip end of the light shielding portion has a step in a vertical direction corresponding to a shape of a cutoff line of a light distribution pattern of the low beam.

In the vehicle headlamp, a part of the first light and a part of the second light directly pass through the projection lens. That is, a part of the first light and a part of the second light are incident on the projection lens without being reflected and pass through the projection lens. In this way, since it is assumed that a part of the first light and a part of the second light are directly incident on the projection lens, the vehicle headlamp does not need a large reflector as described in patent document 1. Another part of the first light is reflected by the first reflection surface of the light shielding portion disposed below the first light-emitting element and incident on the projection lens, and another part of the second light is reflected by the second reflection surface of the light shielding portion disposed above the second light-emitting element and incident on the projection lens. Therefore, the first light and the second light can be effectively used. Further, in the vehicle headlamp, the cutoff line of the light distribution pattern of the low beam is formed by the front end of the light blocking portion. As described above, in the vehicle headlamp, the first light and the second light can be efficiently incident on the projection lens without using a large reflector, and the cutoff line of the light distribution of the low beam can be formed. Therefore, the vehicle headlamp can be prevented from being enlarged.

In addition, it is preferable that the first light-emitting elements are provided in a plurality in parallel in the left-right direction, and the first light-emitting elements disposed on one side in the left-right direction and the first light-emitting elements disposed on the other side are different in installation height from each other with respect to a specific first light-emitting element.

When the low beam is irradiated to the vertical plane, the cut-off line of the light distribution pattern of the low beam is set to have different heights on one side and the other side in the left-right direction with respect to a specific position. Therefore, it is preferable that the front end of the light shielding portion forming the cutoff line has a different height on one side and the other side in the left-right direction with reference to a specific position. Here, by arranging the plurality of first light-emitting elements at different heights as described above, the position of the emission surface of each first light-emitting element can be easily matched with the height of the front end of the light shielding portion. Therefore, the first light emitted from each of the first light-emitting elements easily reaches the vicinity of the tip of the light-shielding portion that forms the cutoff line of the light distribution pattern of the low beam, and the light intensity in the vicinity of the cutoff line can be increased in the light distribution pattern of the low beam.

In addition, it is preferable that an average interval between the specific first light-emitting element and the pair of first light-emitting elements arranged so as to sandwich the specific first light-emitting element is smaller than an average interval between the other plurality of first light-emitting elements adjacent to each other.

By adjusting the average interval between the plurality of first light-emitting elements as described above, the average interval between the plurality of first light-emitting elements disposed adjacent to each other in the vicinity of the center in the left-right direction can be made smaller than the average interval between the plurality of first light-emitting elements disposed adjacent to each other on both ends in the left-right direction. Therefore, as compared with the case where the same number of first light-emitting elements are arranged at equal intervals, the light distribution pattern of the low beam can be made bright in the vicinity of the center of the light distribution pattern of the low beam while spreading to the left and right.

In addition, it is preferable that the specific first light-emitting element and the step of the front end of the light-shielding portion overlap each other in a vertical direction when viewed from the front, the plurality of first light-emitting elements arranged on one side in the horizontal direction with respect to the specific first light-emitting element are provided at positions lower than the plurality of first light-emitting elements arranged on the other side, and the front end of the light-shielding portion is formed so that one side in the horizontal direction is lower than the other side with respect to the step.

By arranging the plurality of first light-emitting elements in this manner and forming the front end of the light-shielding portion, the plurality of first light-emitting elements can be arranged along the shape of the front end of the light-shielding portion. Therefore, the first light emitted from each of the first light-emitting elements can more easily reach the vicinity of the tip of the light-shielding portion that forms the cutoff line of the light distribution pattern of the low beam, and the light intensity in the vicinity of the cutoff line can be further increased in the light distribution pattern of the low beam.

Preferably, a rear end of the first reflecting surface has a step corresponding to a shape of a cutoff line of the light distribution pattern of the low beam.

The front end of the light shielding portion and the rear end of the first reflecting surface on the upper surface of the light shielding portion are respectively provided with a step corresponding to the shape of the cutoff line of the light distribution of the low beam, so that the first light can more easily reach the vicinity of the front end of the light shielding portion. Therefore, the light intensity in the vicinity of the cutoff line can be further increased in the light distribution pattern of the low beam.

Further, it is preferable that the step of the front end of the light shielding portion and the step of the rear end of the first reflecting surface overlap each other in the vertical direction when viewed from the front.

By forming the light shielding portion in this manner, the first light can more easily reach the vicinity of the tip of the light shielding portion. Therefore, the light intensity in the vicinity of the cutoff line can be further increased in the light distribution pattern of the low beam.

Effects of the invention

As described above, according to the present invention, it is possible to provide a vehicle headlamp capable of suppressing an increase in size.

Drawings

Fig. 1 is a diagram illustrating a vehicle headlamp according to an embodiment of the present invention.

Fig. 2 is a perspective view of the lamp unit and the support unit shown in fig. 1.

Fig. 3 is an exploded perspective view of the lamp unit shown in fig. 1 as viewed from the front.

Fig. 4 is an exploded perspective view of the lamp unit shown in fig. 1 as viewed from the rear.

Fig. 5 is a perspective view of the heat sink.

Fig. 6 is a schematic sectional view of the heat sink.

Fig. 7 is a front view of the first substrate, the second substrate, and the flexible printed circuit substrate.

Fig. 8 is an enlarged view of a portion surrounded by a broken line VIII in fig. 7.

Fig. 9 is a diagram showing a state where the first substrate is mounted on a heat sink.

Fig. 10 is a diagram showing a state in which the first substrate and the second substrate are mounted on the heat sink.

Fig. 11 is a view showing a state where the second substrate is mounted on the heat sink.

Fig. 12 is a schematic sectional view through the flexible printed circuit board in fig. 10.

Fig. 13 is a perspective view of the light source unit.

Fig. 14 is a front view of the light source unit.

Fig. 15 is an enlarged view of a portion surrounded by a broken line XV in fig. 14.

Fig. 16 is a schematic cross-sectional view of the light source unit.

Fig. 17 is a perspective view of the support plate as viewed from the front.

Fig. 18 is a perspective view of the support plate as viewed from the rear.

Fig. 19 is a view showing the second substrate in fig. 10 in a plan view.

Fig. 20 is a view showing a state where the second substrate is fixed to the heat sink.

Fig. 21 is a schematic sectional view of the lamp unit.

Fig. 22 is a view showing a light distribution pattern.

Description of the reference numerals

1: a vehicle headlamp; 3: a lamp unit; 20: a projection lens; 40: a reflector unit; 43: a light shielding portion; 43 a: a first reflective surface; 43 as: a convex surface portion; 43 c: a front end; 43 cs: a step; 43 d: a back end; 43 ds: a step; 55: a first light emitting element; 63: a second light emitting element.

Detailed Description

Hereinafter, a mode for implementing the vehicle headlamp according to the present invention will be described by way of example with reference to the accompanying drawings. The following embodiments are provided for the purpose of facilitating understanding of the present invention and are not intended to be limiting. The present invention can be modified and improved according to the following embodiments without departing from the scope of the present invention.

First, the structure of the vehicle headlamp of the present embodiment will be described.

Fig. 1 is a diagram illustrating a lamp including a light source unit according to the present embodiment. In the present embodiment, the lamp is a vehicle headlamp. Generally, vehicle headlamps are provided in the left and right directions in front of a vehicle, and the left and right headlamps are configured to be substantially symmetrical in the left and right directions. Therefore, in the present embodiment, one vehicle headlamp will be described.

As shown in fig. 1, a vehicle headlamp 1 of the present embodiment includes a housing 2, a lamp unit 3, and a support unit 4 as main components. Fig. 1 is a side view of the vehicle headlamp 1, and fig. 1 shows the housing 2 in a cross-sectional view for easy understanding.

Next, the case 2 will be explained.

The housing 2 includes a lamp housing 11, a front cover 12, and a rear cover 13 as main components. A front cover 12 having light permeability is fixed to the lamp housing 11 so as to close the opening of the lamp housing 11. An opening smaller than the opening in the front is formed in the rear of the lamp housing 11, and a rear cover 13 is fixed to the lamp housing 11 to close the opening.

A space formed by the lamp housing 11, the front cover 12 closing the front opening of the lamp housing 11, and the rear cover 13 closing the rear opening of the lamp housing 11 is defined as a lamp chamber R. The lamp unit 3 and the support unit 4 are housed in the lamp chamber R.

Next, the support unit 4 will be explained.

Fig. 2 is a perspective view of the lamp unit and the support unit shown in fig. 1. As shown in fig. 1 and 2, the support unit 4 includes a bracket 15, a first link arm 16a, and a second link arm 16b as main components. The bracket 15 is a frame-shaped body, and includes a base portion 15a extending in the left-right direction, column portions 15b, 15c extending upward from both left and right end portions of the base portion 15a, respectively, and a support portion 15d extending in the left-right direction and connected to upper end portions of the two column portions 15b, 15 c. The lamp unit 3 is disposed between the pedestal portion 15a and the support portion 15 d. The upper portion of the lamp unit 3 and the support portion 15d of the bracket 15 are connected by a first connecting arm 16a, and the lamp unit 3 is suspended from the support portion 15d of the bracket 15. The lower portion of the lamp unit 3 and the base portion 15a of the bracket 15 are coupled by a second connecting arm 16b, and the base portion 15a side of the second connecting arm 16b is coupled to a driving unit, not shown, attached to the base portion 15a via a gear, not shown, and the like. In this way, the lamp unit 3 is attached to the bracket 15 via the first connecting arm 16a and the second connecting arm 16 b. The lamp unit 3 is rotatable in the left-right direction and tiltable in the front-rear direction with respect to the bracket 15 by a drive unit, not shown, attached to the base portion 15 a. The bracket 15 is fixed to the housing 2 by a mechanism not shown.

Next, the lamp unit 3 will be explained.

Fig. 3 is an exploded perspective view of the lamp unit shown in fig. 1 as viewed from the front. Fig. 4 is an exploded perspective view of the lamp unit shown in fig. 1 as viewed from the rear. Fig. 3 and 4 also show the first connecting arm 16a and the second connecting arm 16b of the support unit 4. As shown in fig. 3 and 4, the lamp unit 3 of the present embodiment includes a projection lens 20, a lens holder 25, and a light source unit LU as main components.

Next, the light source unit LU will be explained.

As shown in fig. 3 and 4, the light source unit LU of the present embodiment includes, as main components, a support plate 30, a reflector unit 40, a first substrate 50, a second substrate 60, two flexible printed circuit boards 70, a heat sink 80, and a fan 81.

Next, the heat sink 80 will be explained.

Fig. 5 is a perspective view of the heat sink, and fig. 6 is a schematic sectional view of the heat sink. Fig. 6 also shows a fan 81. As shown in fig. 4 to 6, the heat sink 80 is formed of, for example, metal, and includes a first bottom plate 82, a second bottom plate 83, a peripheral wall portion 84, and a rectifying plate 85 as main components.

The first bottom plate 82 is a plate-like body extending obliquely upward in the front direction and rightward and leftward. In the present embodiment, the first mounting surface 86, the first rib 87, the boss 88, and the recess 89 are formed on the front surface 82f of the first base plate 82. The first mounting surface 86 is a surface on which at least a part of the first board 50 is mounted, and is an end surface of the base 90 that protrudes forward from the front surface 82f of the first base plate 82, and is substantially parallel to the front surface 82f of the first base plate 82. The term "substantially parallel" in the present specification includes a completely parallel state, and also includes a state in which one of the two is inclined by about 1 ° with respect to the other. Of the outer edges of the first mounting surface 86, an outer edge 86e located at the lower end extends in the left-right direction.

As shown in fig. 5, a first rib 87 is formed in a region below the front surface 82f of the first bottom plate 82, and the first rib 87 projects forward from the front surface 82 f. Therefore, the first rib 87 is inclined with respect to the normal line of the first mounting surface 86. The first rib 87 extends upward from below when the first mounting surface 86 is viewed in plan, and is inclined upward with respect to the first mounting surface 86. In the present embodiment, the first rib 87 has a circular cross section perpendicular to the longitudinal direction.

Two bosses 88 are formed above the first ribs 87, and the bosses 88 protrude forward from the front surface 82f of the first bottom plate 82, similarly to the first ribs 87. Therefore, the bosses 88 are inclined with respect to the normal line of the first mounting surface 86. Each boss 88 extends upward from below when the first mounting surface 86 is viewed in plan, and is inclined upward with respect to the first mounting surface 86. An abutment surface 88s substantially perpendicular to the first mounting surface 86 is formed on the outer peripheral surface of the boss 88 on the lower side. In addition, the substantially vertical state in this specification includes a completely vertical state, and also includes a state in which one is inclined by about 1 ° with respect to the other from the completely vertical state. In the present embodiment, the abutment surface 88s of each boss 88 is a plane extending in the left-right direction when the first mounting surface 86 is viewed in plan, and is not parallel to the vertical direction, which is the extending direction of the first rib 87 when the first mounting surface 86 is viewed in plan.

Concave portions 89 are formed on the right and left sides of the first mounting surface 86. The recessed portion 89 is a portion where the front surface 82f of the first base plate 82 is recessed on the side opposite to the first placement surface 86 side. In the present embodiment, the concave portion 89 is recessed in an arc shape in a vertical cross section as will be described later.

The second bottom plate 83 is a plate-like body extending obliquely downward and leftward and rightward in the front direction. The outer edge of the upper side of the second bottom plate 83 is connected to the outer edge of the lower side of the first bottom plate. In the present embodiment, the second mounting surface 91, the second rib 92, the rib reinforcing portion 93, the protrusion 94, and the two bosses 100 are formed on the front surface 83f of the second bottom plate 83. The second mounting surface 91 is a surface on which at least a part of the second substrate 60 is mounted, and is an end surface of the base 95 protruding forward from the front surface 83f of the second bottom plate 83, and is substantially parallel to the front surface 83f of the second bottom plate 83. Therefore, a normal line extending toward the second substrate 60 of the second mounting surface 91 intersects with a normal line extending toward the first substrate 50 of the first mounting surface 86, and an angle formed between the first mounting surface 86 and the second mounting surface 91 is less than 180 degrees. Therefore, the first mounting surface 86 and the second mounting surface 91 are not parallel to each other, and the angle formed by the first substrate 50 and the second substrate 60 is also smaller than 180 degrees. Further, since the first bottom plate 82 and the second bottom plate 83 are plate-shaped bodies, the back surface 82b of the first bottom plate 82 is inclined with respect to the back surface 83b of the second bottom plate 83, and the angle formed between the back surface 82b of the first bottom plate 82 and the back surface 83b of the second bottom plate 83 is larger than 180 degrees. Specifically, the back surface 82b of the first bottom plate 82 is inclined obliquely upward toward the front, and the back surface 83b of the second bottom plate 83 is inclined obliquely downward toward the front. Fig. 6 is a cross-sectional view perpendicular to the front surface 82f of the first base plate 82 and the front surface 83f of the second base plate 83. Since the first bottom plate 82 and the second bottom plate 83 are each a plate-like body as described above, fig. 6 is also a cross-sectional view perpendicular to the back surface 82b of the first bottom plate 82 and the back surface 83b of the second bottom plate 83. Further, an outer edge 91e of the outer edge of the second mounting surface 91, which is positioned at the upper end on the first mounting surface 86 side, is substantially parallel to an outer edge 86e of the outer edge of the first mounting surface 86, which is positioned at the lower end on the second mounting surface 91 side.

As shown in fig. 5, a second rib 92 is formed in a region below the front surface 83f of the second bottom plate 83, and the second rib 92 projects forward from the front surface 83f of the second bottom plate 83. Therefore, the second ribs 92 are inclined with respect to the normal line of the second mounting surface 91. The second rib 92 extends downward from above and is inclined downward with respect to the second mounting surface 91 when the second mounting surface 91 is viewed in plan. In the present embodiment, the second rib 92 has a circular cross section perpendicular to the longitudinal direction. The second rib 92 and the first rib 87 are substantially parallel to each other. The second mounting surface 91 is visible when viewed from the front, which is the front end side of the first rib 87 in the extending direction of the first rib 87. Further, the first mounting surface 86 can be visually recognized when viewed from the front, which is the front end side of the second rib 92 in the extending direction of the second rib 92.

A rib reinforcing portion 93 is formed on the lower side of the outer peripheral surface of the second rib 92, and the rib reinforcing portion 93 is connected to the front surface 83f of the second bottom plate 83. The rib reinforcing portion 93 prevents the second rib 92 from falling downward with respect to the second mounting surface 91. In addition, the strength of the second rib 92 is improved as compared with the case where the rib reinforcing portion 93 is not provided. In the present embodiment, the rib reinforcing portion 93 is provided so as not to contact the second substrate 60.

Projections 94 are formed on both sides of the second bottom plate 83 in the left-right direction. Each of the projections 94 projects from the front surface 83f of the second bottom plate 83 in the direction normal to the second placement surface 91. Contact surfaces 94s substantially perpendicular to the second mounting surface 91 are formed on the outer peripheral surfaces of the upper and lower sides of the respective projections 94. In the present embodiment, the contact surface 94s is a plane extending in the left-right direction when the second mounting surface 91 is viewed in plan, and the contact surface 94s is not parallel to the vertical direction, which is the extending direction of the second rib 92, when the second mounting surface 91 is viewed in plan. The second rib 92 projects further than the projection 94 in the normal direction of the second mounting surface 91.

Bosses 100 are formed on both sides of the second base plate 83 in the left-right direction, and the projection 94 is located between the bosses 100. Each boss 100 protrudes forward from the front surface 83f of the second bottom plate 83 substantially in parallel with the second rib 92. The tip of each boss 100 is a plane that is substantially vertical and substantially perpendicular to the protruding direction of the boss 100. The substantially vertical state in this specification includes a true vertical state and also includes a state inclined by about 1 ° from the true vertical state. At the tip end of each boss 100, a female thread 100a is formed along the boss 100 from the end surface.

A flow member recess 96 is formed in the first bottom plate 82 between the outer peripheral surface of the lower side of the base 90 and the front surface 83f of the second bottom plate 83 on the upper side of the base 95. The two surfaces are arranged from the first mounting surface 86 side toward the second mounting surface 91 side, and the angle formed by the two surfaces is less than 180 degrees. The flow member recess 96 is connected to the two faces. In the present embodiment, as shown in fig. 6, the flow member recess 96 has a substantially V-shaped vertical cross section. The vertical cross-sectional shape of the flow member recess 96 is not particularly limited, and may be, for example, U-shaped.

As shown in fig. 5, a protrusion 97 protruding forward is formed on the surface of the predetermined flow member recess 96. The projection 97 projects further than the first mounting surface 86 in the normal direction of the first mounting surface 86. An abutment surface 97s substantially perpendicular to the first mounting surface 86 is formed on the upper outer peripheral surface of the projection 97. The abutment surface 97s is located below the abutment surface 88s of the boss 88 formed on the first base plate 82. In the present embodiment, the flow member recess 96 is connected to the outer peripheral surface of the lower side of the base 90 and the front surface 83f of the second bottom plate 83 on the upper side of the base 95. Therefore, the protrusion 97 crosses the flow member recess 96 in the vertical direction. In the present embodiment, two protrusions 97 are formed, and the contact surface 97s is a plane extending in the left-right direction when the first mounting surface is viewed in plan, and the contact surface 97s is not parallel to the vertical direction, which is the extending direction of the first rib 87, when the first mounting surface 86 is viewed in plan.

The peripheral wall portion 84 is a cylindrical body extending in the front-rear direction. As shown in fig. 4, a part of the front end of the peripheral wall portion 84 is fixed to the back surface 82b of the first bottom plate 82 and the back surface 83b of the second bottom plate 83. The rear end of the peripheral wall portion 84 is an open end, and an opening 84H is formed. In the present embodiment, the peripheral wall portion 84 is constituted by a pair of side walls 84a, an upper wall 84b, and a lower wall 84 c. The pair of side walls 84a, 84a are plate-like bodies extending in the front-rear direction and the up-down direction at a predetermined interval. The front outer edges of the pair of side walls 84a, 84a are connected to the rear surface 82b of the first bottom plate 82 and the rear surface 83b of the second bottom plate 83 from the upper outer edge of the first bottom plate 82 to the lower outer edge of the second bottom plate 83. As shown in fig. 6, the upper wall 84b is a plate-like body that is positioned above the upper outer edge of the first bottom plate 82, connects the upper outer edges of the pair of side walls 84a, and extends in the front-rear direction and the left-right direction. The lower wall 84c is a plate-like body that is positioned below the lower outer edge of the second bottom plate 83, connects the lower outer edges of the pair of side walls 84a, and extends in the front-rear direction and the left-right direction.

The heat sink 80 is provided with a first air vent 98a defined by the inner surface of the upper wall 84b and the upper outer edge of the first bottom plate 82. The first vent 98a is disposed forward of the connection portion 99 between the first bottom plate 82 and the second bottom plate 83 and on the first bottom plate 82 side of the connection portion 99. The heat sink 80 is formed with a second air vent 98b defined by an inner surface of the lower wall 84c and an outer edge of the lower side of the second bottom plate 83. The second ventilation port 98b is disposed at a position forward of the connection portion 99 between the first bottom plate 82 and the second bottom plate 83 and on the second bottom plate 83 side of the connection portion 99. The first vent 98a and the second vent 98b communicate the internal space and the external space of the peripheral wall portion 84.

The rectifying plate 85 is a plate-like body disposed in the internal space of the peripheral wall portion 84 and extending from the front end side to the rear end side of the peripheral wall portion 84. As shown in fig. 4, in the present embodiment, the rectifying plate 85 extends in the front-rear direction and the up-down direction, the upper outer edge of the rectifying plate 85 is connected to the inner peripheral surface of the upper wall 84b of the peripheral wall portion 84, and the lower outer edge of the rectifying plate 85 is connected to the inner peripheral surface of the lower wall 84c of the peripheral wall portion 84. As shown in fig. 6, the front outer edge 85f of the rectifying plate 85 is connected to the back surface 82b of the first bottom plate 82 and the back surface 83b of the second bottom plate 83. The outer edge 85b of the rectifying plate 85 on the rear side is positioned on the front side of the opening 84H. In fig. 6, the outer edge 85f on the front side and the outer edge 85b on the rear side of the rectifying plate 85 are shown by broken lines. In the present embodiment, the heat sink 80 includes a plurality of flow rectification plates 85. The plurality of baffle plates 85 respectively cross the first vents 98a when viewed from the front in the opening direction of the first vents 98a, and cross the second vents 98b when viewed from the front in the opening direction of the second vents 98 b. Further, some of the plurality of baffle plates 85 have protrusions 85a extending forward from the second vent 98b and protruding toward the space outside the peripheral wall portion 84.

Next, the fan 81 will be explained.

As shown in fig. 6, the fan 81 is disposed rearward of the rectifying plate 85 in the internal space of the peripheral wall portion 84, and the outer periphery of the fan 81 is surrounded by the peripheral wall portion 84. The fan 81 is fixed to the heat sink 80 by screws 81a shown in fig. 4. In the present embodiment, the fan 81 sends air to the back surface 82b of the first bottom plate 82 and the back surface 83b of the second bottom plate 83. That is, the air flow direction between the rear surfaces 82b and 83b and the fan 81 is from the rear to the front. The fan 81 is configured to be capable of switching the air blowing direction to the opposite direction. That is, the fan 81 can also send air to the opening 84H side by switching the air blowing direction to the opposite direction, instead of sending air to the back surface 82b of the first bottom plate 82 and the back surface 83b of the second bottom plate 83. As described above, the first vent 98a and the second vent 98b are located forward of the connection portion 99 of the first bottom plate 82 and the second bottom plate 83, respectively. Therefore, the first air vent 98a and the second air vent 98b are disposed on the opposite side of the connection portion 99 between the first bottom plate 82 and the second bottom plate 83 from the fan 81 side in the cross section perpendicular to the back surface 82b of the first bottom plate 82 and the back surface 83b of the second bottom plate 83.

Next, the first substrate 50, the second substrate 60, and the flexible printed circuit board 70 will be described.

Fig. 7 is a front view of the first substrate, the second substrate, and the flexible printed circuit substrate. In fig. 3 and 4, the flexible printed circuit board 70 is shown in a bent state, but in fig. 7, the flexible printed circuit board 70 is shown in a non-bent state, and a state in which the first substrate 50 and the second substrate 60 are spread on the same plane is shown.

The first substrate 50 is a plate-like body, and is made of, for example, metal. A through hole 51 penetrating in the plate thickness direction is formed in the first substrate 50. Two first contact surfaces 51s are formed on the inner peripheral surface of the first substrate 50 defining the through-hole 51, and the two first contact surfaces 51s are planes that face each other and are substantially parallel to each other in a range from one surface to the other surface of the first substrate 50. That is, the first contact surface 51s is a part of the inner peripheral surface of the first substrate 50 defining the through-hole 51. The first contact surface 51s is provided substantially perpendicular to the front surface and the back surface of the first substrate 50. The through-hole 51 is formed at a position corresponding to the first rib 87 in the first base plate 82 of the heat sink 80, and the distance between the two first contact surfaces 51s is set to be slightly larger than the outer diameter of the first rib 87. For example, the distance between the two first abutment surfaces 51s may be set to be about 0.05mm to 0.1mm larger than the outer diameter of the first rib 87.

In a plan view of the first substrate 50, a side surface on one side in a direction parallel to the first contact surface 51s is set as a second contact surface 52s substantially perpendicular to the first contact surface 51 s. In addition, when the first substrate 50 is viewed in plan, a positioning concave portion 53 whose outer edge is recessed toward the second contact surface 52s side is formed in the outer edge on the side opposite to the second contact surface 52s side. A third contact surface 53s is formed on a side surface of the first substrate 50 defining the positioning recess 53, and the third contact surface 53s is substantially perpendicular to the first contact surface 51s in a range from one surface of the first substrate 50 to the other surface. The positioning recess 53 is formed at a position corresponding to the boss 88 in the first base plate 82 of the heat sink 80, and two positioning recesses 53 are formed. The distance between the second contact surface 52s and the third contact surface 53s is set to be slightly smaller than the distance between the contact surface 88s of the boss 88 and the contact surface 97s of the protrusion 97 in the heat sink 80. For example, the distance between the second abutment surface 52s and the third abutment surface 53s may be set to be smaller than the distance between the abutment surface 88s of the boss 88 and the abutment surface 97s of the projection 97 by about 0.05mm to 0.1 mm. Further, the first substrate 50 is formed with a notch 54 extending from the outer edge of the second contact surface 52s side to a predetermined position on the opposite side of the second contact surface 52s side. In the present embodiment, two cutouts 54 are formed.

A first light-emitting element 55 and a thermistor 56 are mounted on one surface of the first substrate 50. When the first substrate 50 is viewed in plan, the first light-emitting element 55 is positioned on the second contact surface 52s side, and the thermistor 56 is positioned on the opposite side of the second contact surface 52s side. In the present embodiment, the center of gravity 50G of the first substrate 50 is located between the first light emitting element 55 and the thermistor 56.

The first light emitting element 55 emits the first light as a low beam. That is, the first light-emitting element 55 is a low-beam light-emitting element. The first light emitting element 55 is arranged such that a normal line of an emission surface from which the first light is emitted is directed obliquely downward in the forward direction. Further, a plurality of first light emitting elements 55 are provided in parallel in the left-right direction. In the present embodiment, seven first light emitting elements 55 are provided.

Fig. 8 is an enlarged view of a portion surrounded by a broken line VIII in fig. 7. In a case where it is necessary to separately explain the respective first light-emitting elements 55, as shown in fig. 8, the respective first light-emitting elements 55 are referred to as first light-emitting elements 55a to 55g in order from left to right when viewed from the front. The first light-emitting elements 55a to 55d are provided at positions lower than the first light-emitting elements 55e to 55 g. That is, the plurality of first light-emitting elements 55a to 55c disposed on one side in the left-right direction and the plurality of first light-emitting elements 55e to 55g disposed on the other side are different in installation height from each other with respect to the specific first light-emitting element 55 d. In the present embodiment, the specific first light-emitting element 55d is disposed at the same height as the first light-emitting elements 55a to 55c provided on the left side of the specific first light-emitting element 55d in front view. The heights of the first light-emitting elements 55e to 55g are determined according to the shape of a cutoff line of a light distribution pattern of low beams, which will be described later.

In addition, the average interval between the specific first light-emitting element 55d and the pair of first light-emitting elements 55c, 55e arranged so as to sandwich the specific first light-emitting element 55d is smaller than the average interval between the other first light-emitting elements 55a, 55b, 55f, 55g adjacent to each other. That is, the average interval of the first light-emitting elements 55c, 55d, 55e adjacent to each other is smaller than the average interval of the first light-emitting elements 55a, 55b, 55c adjacent to each other and the average interval of the first light-emitting elements 55e, 55f, 55g adjacent to each other. Therefore, the intervals of the first light-emitting elements 55c, 55d, 55e arranged adjacent to each other in the vicinity of the center in the left-right direction are smaller than the average interval of the first light-emitting elements 55a, 55b, 55c arranged adjacent to each other on one side and the average interval of the first light-emitting elements 55e, 55f, 55g arranged adjacent to each other on the other side in the left-right direction.

As the first light emitting element 55, for example, an LED is used. In the present embodiment, as described above, the plurality of first light-emitting elements 55 are arranged in parallel in the left-right direction. Thus, the first light emitting element 55 is provided as an LED array composed of a plurality of LEDs. The LED arrays are connected in series by a power supply circuit 57 formed on the first substrate 50. The thermistor 56 is connected to a thermistor circuit 58 formed on the first substrate 50. The first light-emitting element 55, the thermistor 56, the power supply circuit 57, and the thermistor circuit 58 are insulated from the first substrate 50 by an insulating layer, not shown, provided on the surface of the first substrate 50.

The second substrate 60 is a plate-like body, and is made of, for example, metal. A through hole 61 penetrating in the plate thickness direction is formed in the second substrate 60. Two first contact surfaces 61s are formed on the inner peripheral surface of the second substrate 60 defining the through-hole 51, and the two first contact surfaces 61s are planes that face each other and are substantially parallel to each other in a range from one surface of the second substrate 60 to the other surface. That is, the first contact surface 61s is a part of the inner peripheral surface of the second substrate 60 defining the through-hole 61. The first contact surface 61s is provided substantially perpendicular to the front surface and the back surface of the second substrate 60. The through-hole 61 is formed at a position corresponding to the second rib 92 in the second base plate 83 of the heat sink 80, and the distance between the two first contact surfaces 61s is set to be slightly larger than the outer diameter of the second rib 92. For example, the distance between the two first abutment surfaces 61s may be set to be about 0.05mm to 0.1mm larger than the outer diameter of the second rib 92.

When the second substrate 60 is viewed in plan, a positioning concave portion 62 that is concave in a direction substantially perpendicular to the first contact surface 61s is formed on the outer edge of the second substrate 60. Two second contact surfaces 62s are formed on the side surface of the second substrate 60 defining the positioning recess 62, and the two second contact surfaces 62s face each other in a range from one surface of the second substrate 60 to the other surface thereof and are substantially perpendicular to the first contact surface 61 s. The positioning recess 62 is formed at a position corresponding to the protrusion 94 of the second bottom plate 83 of the heat sink 80, and two positioning recesses 62 are formed in the second substrate 60. The distance between the two second abutment surfaces 62s in each positioning recess 62 is set to be slightly larger than the distance between the two abutment surfaces 94s in the protrusion 94. For example, the distance between the two second abutment surfaces 62s may be set to be about 0.05mm to 0.1mm larger than the distance between the two abutment surfaces 94s in the protrusion 94.

A second light-emitting element 63 and a connector 64 are mounted on one surface of the second substrate 60. In a plan view of the second substrate 60, the second light-emitting element 63 is located on one side in a direction parallel to the first contact surface 61s, and the connector 64 is located on the other side. In the present embodiment, the center of gravity 60G of the second substrate 60 is located between the second light emitting element 63 and the connector 64.

The second light emitting element 63 and the connector 64 are electrically connected by a power supply circuit 65 formed on the second substrate 60. The second light emitting element 63 is disposed below the first light emitting element 55 and emits the second light. The second light emitting element 63 of the present embodiment emits the second light which becomes the high beam. That is, the second light emitting element 63 of the present embodiment is a high beam light emitting element. The second light emitting element 63 is arranged such that the normal line of the emission surface from which the second light is emitted is directed obliquely upward in the forward direction. Further, a plurality of second light emitting elements 63 are provided in parallel in the left-right direction. In the present embodiment, 12 second light emitting elements 63 are provided. The second light emitting elements 63 are arranged on a straight line at substantially the same height. In the present embodiment, one second light-emitting element 63 arranged on the right end is arranged so as to be separated from the other second light-emitting elements 63 by a larger distance than the distance between the other adjacent second light-emitting elements 63.

As such a second light emitting element 63, for example, an LED is used. In the present embodiment, as described above, the plurality of second light emitting elements 63 are provided in parallel in the left-right direction. Therefore, the second light emitting element 63 is provided as an LED array composed of a plurality of LEDs. In the present embodiment, the second light emitting element 63 is an LED array including a plurality of LEDs arranged in parallel in a direction perpendicular to the first contact surface 61s in a plan view of the second substrate 60. In this LED array, two adjacent LEDs are connected in parallel by the power supply circuit 65, and light can be emitted or not emitted in units of two LEDs connected in parallel.

The second substrate 60 is provided with a first power feeding wiring 66a, a second power feeding wiring 66b, a first thermistor wiring 67a, and a second thermistor wiring 67b, each of which has one end connected to the connector 64. In the present embodiment, the first thermistor wire 67a is located closer to the power feeding circuit 65 in a direction substantially perpendicular to the first contact surface 61s in a plan view of the second substrate 60. In a plan view of the second substrate 60, the first power feeding wiring 66a is located between the power feeding circuit 65 and the first thermistor wiring 67a in a direction substantially perpendicular to the first contact surface 61 s. The second thermistor wire 67b is located on the other side of the feeding circuit 65 in the direction substantially perpendicular to the first contact surface 61s in a plan view of the second substrate 60. The second power feeding wiring 66b is located between the power feeding circuit 65 and the second thermistor wiring 67b in a direction substantially perpendicular to the first contact surface 61s in a plan view of the second substrate 60. A not-shown wire harness is connected to the connector 64. The number of the connectors 64 is not particularly limited, and fig. 7 shows an example in which two connectors 64 are mounted in parallel in a direction substantially perpendicular to the first contact surface 61 s. The second light-emitting element 63, the power supply circuit 65, the first power supply wiring 66a, the second power supply wiring 66b, the first thermistor wiring 67a, and the second thermistor wiring 67b are insulated from the second substrate 60 by an insulating layer, not shown, provided on the surface of the second substrate 60.

In the present embodiment, the two flexible printed circuit boards 70 are configured to be substantially bilaterally symmetrical. Hereinafter, one will be described, and the description of the other will be appropriately omitted. The flexible printed circuit board 70 has flexibility, and is composed of, for example, an insulating sheet and a metal film provided on one surface of the insulating sheet. The flexible printed circuit board 70 of the present embodiment includes a substantially rectangular tape portion 73, a first connection portion 71 connected to one end of the tape portion 73 in the longitudinal direction, and a second connection portion 72 connected to the other end of the tape portion 73 in the longitudinal direction. The width of the belt portion 73 in the direction perpendicular to the longitudinal direction is set smaller than the width of the first connection portion 71 and the second connection portion 72 in the direction. In the present embodiment, the band portion 73 is formed with a slit 73s substantially parallel to the longitudinal direction of the band portion 73. With this slit 73s, the bending rigidity of the belt portion 73 is reduced as compared with the case where the slit 73s is not formed. In particular, the rigidity of the belt portion 73 in the direction perpendicular to the longitudinal direction is reduced. The widths of the first connection portion 71, the second connection portion 72, and the belt portion 73 are not particularly limited. For example, the width of the belt portion 73 may be set to be larger than the widths of the first connection portion 71 and the second connection portion 72. The width of the belt portion 73 may vary in the longitudinal direction of the belt portion 73. The band 73 may not have the slit 73 s.

The first connection portion 71 is provided with a first power supply terminal 74a and a first thermistor terminal 75a, and the second connection portion 72 is provided with a second power supply terminal 74b and a second thermistor terminal 75 b. Further, the flexible printed circuit board 70 is provided with a power feeding wiring 74c for electrically connecting the first power feeding terminal 74a and the second power feeding terminal 74b through the tape portion 73. Further, a thermistor wire 75c is formed to electrically connect the first thermistor terminal 75a and the second thermistor terminal 75b through the band 73 similarly to the power supply wire 74 c. The power feeding wire 74c passes through one side of the tape portion 73 in a direction perpendicular to the longitudinal direction with reference to the slit 73s of the tape portion 73. On the other hand, the thermistor wire 75c passes through the other side of the tape portion 73 in the direction perpendicular to the longitudinal direction with reference to the slit 73s of the tape portion 73. That is, the flexible printed circuit board 70 has two wires 74c, 75c extending from the first connection portion 71 to the second connection portion 72, and a gap 73s is formed between the two wires 74c, 75 c.

Each of the flexible printed circuit boards 70 connects the first substrate 50 and the second substrate 60, and electrically connects the circuit formed on the first substrate 50 and the circuit formed on the second substrate 60. Specifically, the first connection portions 71 of the flexible printed circuit boards 70 are bonded to the mounting surface of the first substrate 50 on which the first light-emitting elements 55 are mounted, for example, by solder. The second connection portions 72 of the flexible printed circuit boards 70 are bonded to the mounting surface of the second substrate 60 on which the second light-emitting elements 63 are mounted, for example, by solder. In this way, the respective flexible printed circuit substrates 70 are connected to the first substrate 50 and the second substrate 60. The longitudinal directions of the tape portions 73 in the respective flexible printed circuit boards 70 are set to be substantially parallel to each other. In the present embodiment, the first contact surface 51s of the first substrate 50 and the first contact surface 61s of the second substrate 60 are substantially parallel to each other in a state where the first substrate 50 and the second substrate 60 are disposed on the same plane. In addition, the first substrate 50 is positioned on the first light-emitting element 55 side at the second substrate 60 on the second light-emitting element 63 side.

The first connection portions 71 of the respective flexible printed circuit boards 70 are located at substantially the same positions in a direction parallel to the first contact surface 51s in a plan view of the first substrate 50. The second connection portions 72 of the flexible printed circuit boards 70 are located at substantially the same positions in a direction parallel to the first contact surface 61s when the second substrate 60 is viewed in plan. The center of gravity 50G of the first substrate 50 and the first light emitting element 55 are located between the first connection portions 71 of the flexible printed circuit board 70. The first connection portion 71 of each flexible printed circuit board 70 is located on the opposite side of the first light-emitting element 55 side with respect to the center of gravity 50G of the first substrate 50. The center of gravity 60G of the second substrate 60 and the second light emitting element 63 are located between the second connection portions 72 of the flexible printed circuit board 70. Further, the center of gravity 50G of the first substrate 50 and the first light-emitting element 55 may not be located between the first connection portions 71. Further, the center of gravity 60G of the second substrate 60 and the second light emitting element 63 may not be located between the second connection portions 72. When viewed from the side of the flexible printed circuit board 70 opposite to the first substrate 50 side, a part of the tape portion 73 of each flexible printed circuit board 70 overlaps the notch 54 of the first substrate 50. The width of the slit 54 is set larger than the width of the belt portion 73. In the same viewing angle, the tape portion 73 of each flexible printed circuit board 70 does not overlap the first substrate 50 from the outer edge of the second substrate 60 across which the tape portion 73 crosses to a predetermined position in the notch 54. The tape portion 73 of the flexible printed circuit board 70 of the present embodiment does not overlap the first substrate 50 from the outer edge of the second substrate 60 across which the tape portion 73 crosses to the outer edge on the opposite side of the second substrate 60 out of the outer edges defining the notch 54 of the first substrate 50. In addition, in a plan view of the first substrate 50, the first light-emitting element 55 of the first substrate 50 is disposed on the second substrate 60 side with respect to the edge portion of the notch 54 on the side opposite to the second substrate side. The first light-emitting element 55 overlaps a portion of the band portion 73 that does not overlap the first substrate 50 in the manner described above, in a direction perpendicular to the longitudinal direction of the band portion 73.

Further, a cathode-side end 57c of the feeding circuit 57 formed on the first substrate 50 is connected to the first feeding terminal 74a of the one flexible printed circuit substrate 70. The anode-side end 57a of the feeding circuit 57 of the first substrate 50 is connected to the first feeding terminal 74a of the other flexible printed circuit board 70. Further, one end 58c on the cathode side of the thermistor circuit 58 formed on the first substrate 50 is connected to the first thermistor terminal 75a of the one flexible printed circuit board 70. One end 58a on the anode side of the thermistor circuit 58 formed on the first substrate 50 is connected to the first thermistor terminal 75a of the other flexible printed circuit board 70.

One end of the first power feeding wiring 66a of the second substrate 60 on the side opposite to the connector 64 is connected to the second power feeding terminal 74b of one of the flexible printed circuit boards 70. One end of the second power feeding wiring 66b of the second substrate 60 on the side opposite to the connector 64 is connected to the second power feeding terminal 74b of the other flexible printed circuit board 70. Further, one end of the first thermistor wire 67a on the side opposite to the connector 64 side of the second substrate 60 is connected to the second thermistor terminal 75b of one of the flexible printed circuit boards 70. One end of the second thermistor wire 67b of the second substrate 60 on the side opposite to the connector 64 is connected to the second thermistor terminal 75b of the other flexible printed circuit board 70.

By connecting the two flexible printed circuit boards 70 to the first substrate 50 and the second substrate 60 in this manner, the connector 64 of the second substrate 60 and the feeder circuit 65 of the first substrate 50 are electrically connected. Further, power is supplied to the first light emitting element 55 of the first substrate 50 via the connector 64. The connector 64 of the second substrate 60 is electrically connected to the thermistor circuit 58 of the first substrate 50, and a current is applied to the thermistor 56 of the first substrate 50.

Next, mounting of the first substrate 50 on the heat sink 80 will be described.

Fig. 9 is a diagram showing a state where the first substrate is mounted on a heat sink. As shown in fig. 9, the first substrate 50 is placed on the first placement surface 86 of the first base plate 82 of the heat sink 80 in a state where the first contact surface 51s is substantially parallel to the vertical direction and the first light-emitting element 55 side is positioned downward. When the first substrate is viewed in plan, the outer edge of the first mounting surface 86 is surrounded by the outer edge of the first substrate 50. In the present embodiment, since the grease as a flow member to be described later is applied to the surface of the first substrate 50 opposite to the side on which the first light-emitting element 55 is mounted, the grease is sandwiched between the surface of the first substrate 50 opposite to the side on which the first light-emitting element 55 is mounted and the first mounting surface 86. The first rib 87 of the first base plate 82 is inserted into the through hole 51 of the first base plate 50. As described above, since the first ribs 87 are inclined upward with respect to the first mounting surface 86 and extend upward from below when the first mounting surface 86 is viewed in plan, the first ribs 87 are inserted in a state inclined upward with respect to the opening direction of the through-hole 51. The center of the first rib 87 inserted into the through-hole 51 in this way is located between the two first abutment surfaces 51s when viewed from the front as the extending direction of the first rib 87. As described above, the distance between the two first abutment surfaces 51s is set to be slightly larger than the outer diameter of the first rib 87. Therefore, when the first substrate 50 moves along the first placement surface 86 in the direction perpendicular to the first contact surfaces 51s with respect to the heat sink 80, the outer peripheral surface of the first rib 87 contacts one of the two first contact surfaces 51 s. Here, as described above, when the first mounting surface 86 is viewed in a plan view, the first rib 87 extends upward from below, and the first contact surface 51s is substantially parallel to the vertical direction. Therefore, it can be understood that at least one of the outer peripheral surface on one side and the outer peripheral surface on the other side of the first rib 87 in the left-right direction, which is a direction perpendicular to the extending direction of the first rib 87 in a plan view of the first mounting surface 86, abuts against the first abutment surface 51 s. Therefore, the position of the first substrate 50 relative to the heat sink 80 in the direction parallel to the first mounting surface 86, in the direction perpendicular to the extending direction of the first ribs 87 when the first mounting surface 86 is viewed in plan, is limited to a predetermined range. In addition, at least one of the outer peripheral surface of one side and the outer peripheral surface of the other side of the first rib 87 in the direction perpendicular to the extending direction of the first rib 87 in a plan view of the first mounting surface 86 may always abut against the first abutment surface 51 s. For example, the first rib 87 may be pressed into the through-hole 51.

The two bosses 88 of the first base plate 82 enter the two positioning recesses 53 of the first base plate 50, respectively. As described above, the abutment surface 88s of the boss 88 is a flat surface perpendicular to the first mounting surface 86 and extending in the left-right direction when the first mounting surface 86 is viewed in plan. The third contact surface 53s on the side surface of the first substrate 50 defining the positioning recess 53 is set to be substantially perpendicular to the first contact surface 51s substantially parallel to the vertical direction. Therefore, the contact surface 88s and the third contact surface 53s face each other in a substantially parallel state.

The second contact surface 52s of the first substrate 50 is located above the protrusion 97 of the heat sink 80. As described above, the contact surface 97s of the projection 97 is a flat surface that is substantially perpendicular to the first mounting surface 86 and extends in the left-right direction when the first mounting surface 86 is viewed in plan. The second contact surface 52s of the first substrate 50 is substantially perpendicular to the first contact surface 51s substantially parallel to the vertical direction. Therefore, the contact surface 97s and the second contact surface 52s face each other in a substantially parallel state. As described above, the distance between the second abutment surface 52s and the third abutment surface 53s in the first substrate 50 is set to be slightly smaller than the distance between the abutment surface 88s of the boss 88 and the abutment surface 97s of the protrusion 97 in the heat sink 80. Therefore, when the first substrate 50 moves along the first placement surface 86 in a direction parallel to the first contact surface 51s with respect to the heat sink 80, the second contact surface 52s of the first substrate 50 contacts the contact surface 97s of the protrusion 97. Further, the third abutment surface 53s of the first substrate 50 abuts against the abutment surface 88s of the boss 88. Here, as described above, in a plan view of the first placement surface 86, the contact surface 88s is a flat surface extending in the left-right direction, and the contact surface 88s and the third contact surface 53s face each other in a substantially parallel state. Therefore, when the first placement surface 86 is viewed in plan, a tangent line at which the contact surface 88s and the third contact surface 53s contact extends substantially in the left-right direction. Therefore, the tangent line is substantially perpendicular to and not parallel to the extending direction of the first rib 87. As described above, in the case of the first mounting surface 86 as viewed in plan, the contact surface 97s is a flat surface extending in the left-right direction, and the contact surface 97s and the second contact surface 52s face each other in a substantially parallel state. Therefore, when the first placement surface 86 is viewed in plan, a tangent line at the time when the contact surface 97s and the second contact surface 52s contact each other extends substantially in the left-right direction. Therefore, the tangent line is substantially perpendicular to and not parallel to the extending direction of the first rib 87. Therefore, the position of the first substrate 50 relative to the heat sink 80 in the direction parallel to the first mounting surface 86 is limited to a predetermined range in the vertical direction, which is the extending direction of the first rib 87 when the first mounting surface 86 is viewed in plan. In at least one of the contact surface 88s and the third contact surface 53s and the contact surface 97s and the second contact surface 52s, the first rib 87 does not contact the first substrate 50 in the extending direction of the first rib 87 when the first placement surface 86 is viewed in plan. The second contact surface 52s of the first substrate 50 and the contact surface 97s of the projection 97 may always be in contact with each other, and the third contact surface 53s of the first substrate 50 and the contact surface 88s of the boss 88 may always be in contact with each other.

Further, since the first bottom plate 82 extends obliquely upward in the forward direction as described above, the first mounting surface 86 also extends obliquely upward in the forward direction, and the first substrate 50 mounted on the first mounting surface 86 also extends obliquely upward in the forward direction. As shown in fig. 9, when viewed from the front in the opening direction of the first vent 98a, a part of the first substrate 50 overlaps the first vent 98 a. As described above, the first substrate 50 is placed on the first placement surface 86 of the heat sink 80 in a state where the first contact surface 51s is substantially parallel to the vertical direction. The first light emitting element 55 is an LED array including a plurality of LEDs arranged in parallel in a direction substantially perpendicular to the first contact surface 51 s. Therefore, the LED arrays as the first light emitting elements 55 are arranged in the left-right direction.

Next, mounting of the second substrate 60 on the heat sink 80 will be described.

Fig. 10 is a diagram showing a state in which the first substrate and the second substrate are mounted on the heat sink. As shown in fig. 10, the second substrate 60 is placed on the second placement surface 91 of the second base plate 83 of the heat sink 80 in a state where the first contact surface 61s is substantially parallel to the vertical direction and the second light-emitting element 63 side is positioned on the upper side. When the second substrate 60 is viewed in plan, the outer edge of the second mounting surface 91 is surrounded by the outer edge of the second substrate 60. In fig. 10, the first substrate 50 side of the second substrate 60 and the second substrate 60 side of the first substrate 50 overlap, but the second substrate 60 and the first substrate 50 are separated. That is, the first substrate 50 and the second substrate 60 are mounted on the heat sink 80 with a predetermined gap therebetween.

In the present embodiment, since the grease as a flow member to be described later is applied to the surface of the second substrate 60 opposite to the side on which the second light-emitting element 63 is mounted, similarly to the first substrate 50, the grease is sandwiched between the surface of the second substrate 60 opposite to the side on which the second light-emitting element 63 is mounted and the second mounting surface 91. The second rib 92 of the second base plate 83 is inserted into the through hole 61 of the second base plate 60. As described above, since the second rib 92 is inclined downward with respect to the second mounting surface 91 and extends downward from above when the second mounting surface 91 is viewed in plan, the second rib 92 is inserted in a state inclined downward with respect to the opening direction of the through-hole 61. The center of the second rib 92 inserted into the through-hole 61 in this way is located between the two first abutment surfaces 61s when viewed from the front as the extending direction of the second rib 92. As described above, the distance between the two first abutment surfaces 61s is set to be slightly larger than the outer diameter of the second rib 92. Therefore, when the second substrate 60 moves along the second placement surface 91 in the direction perpendicular to the first contact surfaces 61s with respect to the heat sink 80, the outer peripheral surface of the second rib 92 contacts one of the two first contact surfaces 61 s. Here, as described above, when the second mounting surface 91 is viewed in plan, the second rib 92 extends downward from above, and the first contact surface 61s is set substantially parallel to the vertical direction. Therefore, it can be understood that at least one of the outer peripheral surface on one side and the outer peripheral surface on the other side of the second rib 92 in the lateral direction, which is the direction perpendicular to the extending direction of the second rib 92 when the second mounting surface 91 is viewed in plan, abuts against the first abutment surface 61 s. Therefore, the position of the second substrate 60 relative to the heat sink 80 in the direction parallel to the second mounting surface 91, in the direction perpendicular to the extending direction of the second ribs 92 when the second mounting surface 91 is viewed in plan, is limited to a predetermined range. In addition, at least one of the outer peripheral surface of one side and the outer peripheral surface of the other side of the second rib 92 in the direction perpendicular to the extending direction of the second rib 92 in a plan view of the second mounting surface 91 may always abut against the first abutment surface 61 s. For example, the second rib 92 may be press-fitted into the through hole 61.

The two protrusions 94 of the second base plate 83 enter the two positioning recesses 62 of the second substrate 60, respectively. As described above, the abutment surfaces 94s formed on the outer peripheral surfaces of the upper and lower sides of the projection 94 are respectively formed as planes that are substantially perpendicular to the second mounting surface 91 and extend in the left-right direction when the second mounting surface 91 is viewed in plan. Two second contact surfaces 62s facing the side surfaces of the second substrate 60 defining the positioning recess 62 are set to be substantially perpendicular to the first contact surface 61s substantially parallel to the vertical direction. Therefore, the contact surface 94s and the second contact surface 62s are opposed to each other in a substantially parallel state. As described above, the distance between the two second abutment surfaces 62s in each positioning concave portion 62 is set to be slightly larger than the distance between the two abutment surfaces 94s in the protrusion 94. Therefore, when the second substrate 60 moves along the second placement surface 91 along the first contact surface 61s with respect to the heat sink 80 in a direction parallel to the first contact surface 61s, the first contact surface 61s and one of the contact surfaces 94s that face each other abut against each other. Here, as described above, the contact surface 94s is a flat surface extending in the left-right direction when the second placement surface 91 is viewed in plan, and the contact surface 94s and the second contact surface 62s face each other in a substantially parallel state. Therefore, when the second placement surface 91 is viewed in plan, a tangent line at which the contact surface 94s and the second contact surface 62s contact each other extends substantially in the left-right direction. Therefore, the tangent line is substantially perpendicular to and not parallel to the extending direction of the second rib 92. Therefore, the position of the second substrate 60 in the direction parallel to the second mounting surface 91 with respect to the heat sink 80, in the direction parallel to the first contact surface 61s, is limited to a predetermined range. In a state where the contact surface 94s and the second contact surface 62s are in contact with each other, the second rib 92 does not contact the second board 60 in the extending direction of the second rib 92 when the second mounting surface 91 is viewed in plan. The second contact surface 62s of the second substrate 60 and the contact surface 94s of the projection 94 may always be in contact with each other. For example, the protrusion 94 may be pressed into the positioning recess 62.

Further, since the second bottom plate 83 extends obliquely forward and downward as described above, the second mounting surface 91 also extends obliquely forward and downward, and the second substrate 60 mounted on the second mounting surface 91 also extends obliquely forward and downward. As shown in fig. 10, the second substrate 60 overlaps the second vent 98b when viewed from the front in the opening direction of the second vent 98 b. As described above, the second substrate 60 is placed on the second placement surface 91 of the heat sink 80 in a state where the first contact surface 61s is substantially parallel to the vertical direction. The second light emitting element 63 is provided as an LED array arranged in a direction substantially perpendicular to the first contact surface 61 s. Therefore, the LED arrays as the second light emitting elements 63 are arranged in the left-right direction. In addition, as described above, since the first light-emitting element 55 side of the first substrate 50 is positioned on the second light-emitting element 63 side of the second substrate 60, the second light-emitting element 63 is positioned on the first substrate 50 side of the second substrate 60 with respect to the second substrate 60 side. The first light-emitting element 55 is located on the second substrate 60 side of the first substrate 50 with respect to the first substrate 50 side.

When viewed from the side of the flexible printed circuit board 70 opposite to the heat sink 80 side, the tape portions 73 of the two flexible printed circuit boards 70 do not overlap with the first substrate 50 from the outer edge of the second substrate 60 across which the tape portions 73 cross to a predetermined position in the notch 54. In addition, in the same viewing angle, the first light-emitting element 55 of the first substrate 50 overlaps the portion of the band portion 73 that does not overlap the first substrate 50 in the direction perpendicular to the longitudinal direction of the band portion 73. In addition, in the same view angle, the concave portion 89 on one side of the heat sink 80 crosses the edges on both sides of the flexible printed circuit board 70 in the direction perpendicular to the longitudinal direction of the flexible printed circuit board 70 on one side. The other concave portion 89 crosses edges on both sides of the other flexible printed circuit board 70 in a direction perpendicular to the longitudinal direction of the other flexible printed circuit board 70.

Fig. 11 is a view showing a state where the second substrate is mounted on the heat sink, and is a partially enlarged view of the second substrate and the heat sink as viewed from the side. As described above, some of the plurality of baffle plates 85 have the protruding portions 85a that extend forward from the second vent ports 98b and protrude toward the space outside the peripheral wall portion 84. As shown in fig. 11, the protruding portion 85a contacts a surface of the second substrate 60 opposite to the side on which the second light-emitting element 63 is mounted. That is, the second substrate 60 is placed on the second placement surface 91 of the second base plate 83 and also on the protruding portion 85 a.

Next, a description will be given of a state of the flexible printed circuit board 70 in a state where the first substrate 50 and the second substrate 60 are mounted on the heat sink 80.

In the present embodiment, the two flexible printed circuit boards 70 are substantially in the same state in a state where the first substrate 50 and the second substrate 60 are mounted on the heat sink 80. Therefore, one will be described below, and the description of the other will be omitted. Fig. 12 is a schematic cross-sectional view through the flexible printed circuit board in fig. 10, and is a schematic cross-sectional view parallel to the longitudinal direction of the tape portion 73 of the flexible printed circuit board 70. As described above, the first connection portion 71 is joined to the mounting surface 50s of the first substrate 50 on which the first light-emitting element 55 is mounted, and the second connection portion 72 is joined to the mounting surface 60s of the second substrate 60 on which the second light-emitting element 63 is mounted. Therefore, the first connection portion 71 is connected to the side opposite to the first mounting surface 86 of the first substrate 50, and the second connection portion 72 is connected to the side opposite to the second mounting surface 91 of the second substrate 60. As shown in fig. 12, the tape portion 73 of the flexible printed circuit board 70 is bent in a convex shape toward the heat sink 80 at a position closer to the first substrate 50 side than the first connection portion 71 between the first substrate 50 and the second substrate 60. In the present embodiment, the tape portion 73 of the flexible printed circuit board 70 passes through the first mounting surface 86 side region with respect to the first connection portion 71 and passes through the notch 54 of the first substrate 50. The concave portion 89 of the heat sink 80 is recessed in an arc shape in a vertical cross section and is recessed toward the opposite side of the first mounting surface 86 to the flexible printed circuit board 70 side. The band portion 73 of the flexible printed circuit board 70 also passes through the concave portion 89. The flexible printed circuit board 70 thus bent does not contact the heat sink 80. Further, for example, due to dimensional errors of the first substrate 50, the second substrate 60, the heat sink 80, and the like, the first substrate 50 and the second substrate 60 may be displaced in the left-right direction, which is a direction perpendicular to the longitudinal direction of the belt portion 73, and a stress may be generated in the left-right direction in the belt portion 73. However, as described above, by forming the slit 73s in the belt portion 73, the rigidity of the belt portion 73 in the direction perpendicular to the longitudinal direction is particularly reduced as compared with the case where the slit 73s is not formed. Therefore, even when a stress in the left-right direction is generated in the belt portion 73, the stress acting on the first connection portion and the second connection portion can be reduced as compared with the case where the slit 73s is not formed, and the occurrence of a problem can be suppressed.

Next, the reflector unit 40 will be explained.

Fig. 13 is a perspective view of the light source unit, fig. 14 is a front view of the light source unit, fig. 15 is an enlarged view of a portion surrounded by a broken line XV in fig. 14, and fig. 16 is a schematic cross-sectional view of the light source unit. As shown in fig. 13 and 14, the reflector unit 40 has, as main components, a reflector 41 for the first light-emitting element 55, a first side reflector 41a for the first light-emitting element 55, a second side reflector 41b for the first light-emitting element 55, a reflector 42 for the second light-emitting element 63, a first side reflector 42a for the second light-emitting element 63, a second side reflector 42b for the second light-emitting element 63, and a light shielding portion 43.

The reflector unit 40 is disposed on the opposite side of the first substrate 50 from the heat sink 80. The reflector unit 40 is fixed to the heat sink 80 so that the first substrate 50 is sandwiched between the reflector unit 40 and the heat sink 80. In the present embodiment, two screws 46 are used to fix the reflector unit 40 to the heat sink 80.

As shown in fig. 4, the reflector unit 40 also has a rib 44. The rib 44 extends toward the first board 50, and a part of one end of the rib 44 on the first board 50 side contacts a mounting surface 50s of the first board 50 on which the first light-emitting element 55 is mounted. Therefore, the first substrate 50 is pressed against the first mounting surface 86 of the heat sink 80 by the reflector unit 40 and fixed to the heat sink 80. In the present embodiment, the reflector unit 40 has a plurality of ribs 44, and when the first substrate 50 is viewed in a plan view, the portions of the ribs 44 that contact the first substrate 50 overlap the first mounting surface 86. Therefore, the first substrate 50 can be more appropriately pressed against the first mounting surface 86, and the relative position of the first substrate 50 with respect to the heat sink 80 can be suppressed from changing due to vibration or the like.

In the present embodiment, as described above, since the grease as the fluid member is applied to the surface of the first substrate 50 opposite to the side on which the first light-emitting element 55 is mounted, the grease 24 is sandwiched between the first substrate 50 and the first mounting surface 86 as shown in fig. 12. Therefore, when the first substrate 50 is pressed against the first mounting surface 86, a part of the grease 24 may be pushed out from between the first substrate 50 and the first mounting surface 86. As described above, the first placement surface 86 is an end surface of the base 90 that protrudes forward from the front surface 82f of the first base plate 82, and the outer edge of the first placement surface 86 is surrounded by the outer edge of the first base plate 50. Therefore, the excess grease 24 pushed out from between the first base plate 50 and the first mounting surface 86 is pushed out onto the front surface 82f of the first base plate 82 around the base 90. Therefore, the adhesion of a part of the excess grease 24 to the mounting surface 50s of the first substrate 50 on which the first light-emitting element 55 is mounted is suppressed, and the adhesion of the excess grease 24 to the first light-emitting element 55 is suppressed.

As shown in fig. 14 to 16, the light shielding portion 43 extends forward from between the first light emitting element 55 and the second light emitting element 63. The light shielding portion 43 has a first reflection surface 43a on the upper surface thereof, which reflects a part of the first light so that the part of the first light emitted from the first light emitting element 55 passes through the projection lens 20.

The first reflecting surface 43a is a reflecting surface that extends forward from the first light emitting element 55 side and is recessed downward in a vertical plane parallel to the front-rear direction. Further, the front end of the first reflecting surface 43a, that is, a part of the front end 43c of the light shielding portion 43 is convex upward, and thus has a step 43cs in the vertical direction as shown in fig. 15. In fig. 15, the front end 43c of the light shielding portion 43 is shown in a thick line for easy viewing. The step 43cs formed at the tip 43c of the light shielding portion 43 is formed to correspond to the shape of a cutoff line of a light distribution pattern of low beam to be described later. The step 43cs of the present embodiment is formed near the center of the front end 43c in the left-right direction. The front end 43c of the light shielding portion 43 is preferably formed to be lower on one side in the left-right direction than on the other side with respect to the step 43 cs. In the present embodiment, specifically, a portion 43cL of the front end 43c on the left side of the step 43cs is lower than a portion 43cH of the front end 43c on the right side of the step 43 cs. The step 43cs is formed in a diagonal line shape between a portion 43cL on the left side of the step 43cs and a portion 43cH on the right side of the step 43 cs.

Further, the specific first light-emitting element 55d and the step 43cs of the front end 43c of the light shielding portion 43 are arranged so as to overlap in the vertical direction when viewed from the front. As described above, the plurality of first light-emitting elements 55a to 55c arranged on one side in the left-right direction with respect to the specific first light-emitting element 55d are provided at positions lower than the plurality of first light-emitting elements 55e to 55g arranged on the other side. Therefore, the first light-emitting elements 55a to 55c arranged at relatively low positions overlap with a portion 43cL of the front end 43c of the light shielding portion 43, which portion is formed as the relatively low front end 43c, in the vertical direction when viewed from the front. In addition, the first light-emitting elements 55e to 55g arranged at relatively high positions overlap with a portion 43cH of the front end 43c of the light shielding portion 43, which portion is formed as the relatively high front end 43c, in the vertical direction when viewed from the front.

Although not explicitly shown, the front end 43c of the light shielding portion 43 is gradually recessed rearward from the left and right ends toward the center in order to form a cutoff line of the light distribution pattern of the low beam.

A part of the rear end 43d of the first reflecting surface 43a is convex upward, and thus has a step 43ds in the vertical direction as shown in fig. 15. Further, in fig. 15, the rear end 43d of the first reflection surface 43a is shown in a thick line for easy viewing. The step 43ds formed at the rear end 43d of the first reflecting surface 43a is formed to correspond to the shape of a cutoff line of a light distribution pattern of low beams, which will be described later. The step 43ds of the present embodiment is formed near the center in the left-right direction, and overlaps the step 43cs of the front end 43c of the light shielding portion 43 in the up-down direction when viewed from the front. Similarly to the step 43cs of the front end 43c of the light shielding portion 43, the rear end 43d of the first reflection surface 43a is formed higher than the portion 43dH on the right side than the step 43ds than the portion 43dL on the left side in front view. In addition, the specific first light emitting element 55d and the step 43ds overlap in the vertical direction when viewed from the front. Step 43ds is formed in an oblique line shape between a portion 43dL on the left side of step 43ds and a portion 43dH on the right side of step 43 ds. In addition, step 43ds of the present embodiment is formed longer than step 43 cs.

As described above, the front end 43c of the light shielding portion 43 and the rear end 43d of the first reflecting surface 43a are formed with steps, respectively, so that the first reflecting surface 43a is formed with the convex surface portion 43as projecting upward so as to extend in the front-rear direction. Further, since step 43ds of the present embodiment is formed longer than step 43cs, convex surface portion 43as is wider as going from the rear to the front. The convex portion 43as is shaped to correspond to the light distribution pattern of the low beam.

The light shielding portion 43 has a second reflecting surface 43b on the lower surface thereof, which reflects a part of the second light so that the part of the second light emitted from the second light emitting element 63 passes through the projection lens 20. The second reflecting surface 43b is a concave reflecting surface that extends forward from the second light emitting element 63 side and reflects a part of the second light forward. As shown in fig. 15, the rear end 43e of the second reflecting surface 43b is formed linearly in the left-right direction. Further, in fig. 15, the rear end 43e of the second reflection surface 43b is shown in a thick line for easy viewing. The plurality of second light emitting elements 63 are arranged on a straight line along the rear end 43e of the second reflecting surface 43b formed in the straight line.

The reflector 41 is disposed above the first light-emitting element 55, and has a third reflection surface 41r on the first light-emitting element 55 side so as to cover the upper side of the first light-emitting element 55. The third reflecting surface 41r and the first reflecting surface 43a of the light shielding portion 43 are a pair of reflectors arranged to extend in the left-right direction and sandwich the first light emitting element 55 from the upper and lower sides.

As shown in fig. 13 and 14, the first side reflector 41a is formed at a position on one side of the first light-emitting element 55 in the left-right direction in the space between the first reflection surface 43a of the light shielding portion 43 and the third reflection surface 41r of the reflector 41. The second side reflector 41b is formed on the other side of the first light-emitting element 55 in the space. The first side reflector 41a and the second side reflector 41b are formed so that the distance therebetween increases from the rear toward the front.

As shown in fig. 16, the reflector 42 is disposed below the second light emitting element 63, and has a fourth reflecting surface 42r on the second light emitting element 63 side to cover the lower side of the second light emitting element 63. The fourth reflecting surface 42r and the second reflecting surface 43b of the light shielding portion 43 are a pair of reflectors arranged to extend in the left-right direction and sandwich the second light emitting element 63 from the upper and lower sides.

As shown in fig. 13 and 14, the first side reflector 42a is formed at a position on one side of the second light-emitting element 63 in the left-right direction in a space between the second reflection surface 43b of the light-shielding portion 43 and the fourth reflection surface 42r of the reflector 42. The second side reflector 42b is formed on the other side of the second light emitting element 63 in the space. The first side reflector 42a and the second side reflector 42b are formed so that the distance therebetween increases from the rear toward the front.

Next, the support plate 30 will be explained.

Fig. 17 is a perspective view of the support plate as viewed from the front, and fig. 18 is a perspective view of the support plate as viewed from the rear. The support plate 30 has elasticity, and as shown in fig. 17 and 18, includes a base portion 31, a pair of fixing portions 32, a pair of first light-shielding portions 33, a second light-shielding portion 34, and a third light-shielding portion 35. In the present embodiment, the base portion 31, the pair of fixing portions 32, the pair of first light-shielding portions 33, the second light-shielding portion 34, and the third light-shielding portion 35 are integrally formed by bending a metal plate. As shown in fig. 13 and 14, the support plate 30 is fixed to the heat sink 80 so as to cover a part of the second substrate 60 from the mounting surface 60s on which the second light-emitting element 63 is mounted.

The base portion 31 is disposed on the opposite side of the second substrate 60 to the heat sink 80 side, and extends along the second substrate 60 between the connector 64 and the second light-emitting element 63. The base portion 31 has a convex portion 31a, and the convex portion 31a protrudes toward the second substrate 60 side and contacts a surface of the second substrate 60 opposite to the second mounting surface 91 side. That is, the convex portion 31a contacts the mounting surface 60s of the second substrate 60 on which the second light emitting element 63 is mounted. In the present embodiment, the base portion 31 has two convex portions 31 a. Fig. 19 is a diagram showing the second substrate in fig. 10 in a plan view, and is an enlarged view of the vicinity of the positioning recess 62. As shown in fig. 7, 10, and 19, the contact portions 31b of the mounting surface 60s of the second substrate 60 on which the second light-emitting element 63 is mounted, which contact the two convex portions 31a, are located on the opposite side of the second substrate 60 from the positioning concave portion 62 toward the second light-emitting element 63. The number and position of the protrusions 31a of the support plate 30 are not particularly limited. In other words, the number and position of the contact portions 31b of the second substrate 60 that contact the convex portions 31a are not particularly limited.

As shown in fig. 17 and 18, one fixing portion 32 of the pair of fixing portions 32 is coupled to one outer edge portion of the base portion 31 in the left-right direction. The other fixing portion 32 is coupled to the outer edge portion of the other side of the base portion 31 in the left-right direction. As shown in fig. 17 and 18, the pair of fixing portions 32 are fixed to two bosses 100 of the heat sink 80 by screws 101.

The pair of fixing portions 32 are configured to be substantially bilaterally symmetrical, and include an inner wall portion 32a, an outer wall portion 32b, and a front wall portion 32 c. The inner wall portion 32a extends in a direction substantially perpendicular to the base portion 31 on the side opposite to the second substrate 60 side with respect to the base portion 31, and is connected to the base portion 31. The front wall portion 32c is located forward of the inner wall portion 32a and on the opposite side of the inner wall portion 32a to the base portion 31. The front wall portion 32c is substantially orthogonal to the inner wall portion 32a, extends substantially in the vertical direction, and is connected to the inner wall portion 32 a. The outer wall portion 32b extends substantially parallel to the inner wall portion 32a at a position rearward of the front wall portion 32c, and is connected to the front wall portion 32 c. The front wall portion 32c extends substantially in the vertical direction, and is formed with a through hole penetrating in the plate thickness direction of the front wall portion 32 c. As described above, the second board 60 extends obliquely forward and downward, and therefore, the second board 60 also extends obliquely forward and downward along the base portion 31. Therefore, the front wall portion 32c of the fixing portion 32 is not parallel to the base portion 31. The boss 100 of the heat sink 80 is disposed in a space surrounded by the inner wall portion 32a, the outer wall portion 32b, and the front wall portion 32c of the fixing portion 32, and the fixing portion 32 is fixed to the heat sink 80 by screws 101.

The second light shielding portion 34 is connected to an outer edge portion of the base portion 31 on the connector 64 side. The second light shielding portion 34 has an upper wall portion 34a and a pair of connecting wall portions 34 b. The upper wall portion 34a is disposed above the connector 64 and extends substantially parallel to the base portion 31. One connecting wall portion 34b is connected to one side in the left-right direction of the outer edge portion of the base portion 31 on the connector 64 side, and extends to the opposite side to the second substrate 60 side. The outer edge portion of the one connecting wall portion 34b on the side opposite to the base portion 31 side is connected to the outer edge portion of the upper wall portion 34a on the second light emitting element 63 side. The other connecting wall portion 34b is connected to the other side in the left-right direction of the outer edge portion of the base portion 31 on the connector 64 side, and extends to the opposite side to the second substrate 60 side. The outer edge portion of the other connecting wall portion 34b on the side opposite to the base portion 31 side is connected to the outer edge portion of the upper wall portion 34a on the second light emitting element 63 side. Such a second light shielding portion 34 covers a part of the connector 64 on the side opposite to the second substrate 60 side.

The third light shielding portion 35 is connected to the first side reflector 41a for the first light emitting element 55 in the outer edge portion of the base portion 31 on the second light emitting element 63 side. The third light-shielding portion 35 has a rear side wall portion 35a, a folded portion 35b, a side wall portion 35c, and a front side wall portion 35d, and shields a part of the first light by the front side wall portion 35 d. The rear side wall portion 35a is disposed on the first side reflector 41a side of the first and second light-emitting elements 55 and 63, among the positions on the opposite side of the second substrate 60 side of the base portion 31. The rear side wall portion 35a extends vertically and laterally and is connected to the base portion 31. The folded portion 35b is disposed at a position on the opposite side of the first side reflector 41a from the first light emitting element 55 side, out of the positions forward of the rear side wall portion 35 a. The folded portion 35b extends substantially parallel to the rear side wall portion 35a, and is connected to the rear side wall portion 35a on the side opposite to the first side reflector 41a side. The side wall portion 35c is disposed at a position on the opposite side of the first side reflector 41a to the first light emitting element 55 side, out of positions forward of the folded portion 35 b. The side wall portion 35c extends in a direction substantially parallel to the inner wall portion 32a of the fixing portion 32, and is connected to the first side reflector 41a side of the folded portion 35 b. The front side wall portion 35d is disposed on the first side reflector 41a side of the first light-emitting element 55 and the second light-emitting element 63, out of the positions forward of the first side reflector 41 a. The front side wall portion 35d extends vertically and laterally and is connected to the side wall portion 35 c. Such a front side wall portion 35d shields a part of the first light emitted from the first light emitting element.

Next, the fixing of the second substrate 60 to the heat sink 80 will be described in detail.

Fig. 20 is a view showing a state where the second substrate is fixed to the heat sink, and is a sectional view of the light source unit LU passing through the convex portion 31a of the base portion 31 of the support plate 30. In fig. 20, the vicinity of the convex portion 31a is shown. As described above, the support plate 30 is fixed to the heat sink 80 by fixing the pair of fixing portions 32 to the bosses 100 of the heat sink 80 with the screws 101. Specifically, the front wall portion 32c of the fixing portion 32 is formed such that the end surface of the boss 100 is substantially parallel to and slightly separated from the front wall portion 32c in a state where the convex portion 31a of the base portion 31 is in contact with the second base plate 60 and the through hole of the front wall portion 32c is aligned with the position of the female screw 100 a. The support plate 30 is fixed to the heat sink 80 by inserting screws 101 into through holes of the front wall 32c and screwing the screws into the female screws 100 a. At this time, the support plate 30 is pressed toward the heat sink 80 by the screw 101 so that the gap between the end face of the boss 100 and the front wall portion 32c is narrowed. Here, since the front wall portion 32c substantially parallel to the end surface of the boss 100 extends substantially in the vertical direction, the support plate 30 is pushed rearward by the screw 101. As described above, the convex portion 31a of the base portion 31 contacts the mounting surface 60s of the second substrate 60 on which the second light-emitting element 63 is mounted. Therefore, the support plate 30 is elastically deformed, and the elastic force of the support plate 30 acts on the contact portion 31b of the second base plate 60. Since the support plate 30 is pushed rearward, the elastic force F acting on the support plate 30 of the contact portion 31b is rearward as shown in fig. 20. The second substrate 60 is fixed to the heat sink 80 by the elastic force F of the support plate 30. Here, as described above, since the second board 60 mounted on the second mounting surface 91 extends obliquely forward and downward, the direction in which the support plate 30 is pushed in and the mounting surface 60s of the second board 60 on which the second light emitting element 63 is mounted are not perpendicular to and parallel to each other. Therefore, the direction of the elastic force F of the support plate 30 is not perpendicular to and parallel to the mounting surface 60s of the second board 60. Therefore, the elastic force F of the support plate 30 is composed of a force F1 directed in a direction perpendicular to the second mounting surface 91 and a force F2 along the second mounting surface 91. Further, since the second board 60 placed on the second placement surface 91 extends obliquely forward and downward, the force F2 along the second placement surface 91 out of the elastic force F of the support plate 30 is directed upward.

The second board 60 is pressed against the second mounting surface 91 by a force F1 directed in a direction perpendicular to the second mounting surface 91 among the elastic forces F of the support plate 30. Further, the second board 60 is pushed upward along the second mounting surface 91 by a force F2 along the second mounting surface 91 out of the elastic forces F of the support plate 30, and a part of the side surface of the second board 60 is pressed by the outer peripheral surface of the protrusion 94 of the heat sink 80. More specifically, as shown in fig. 19, the second abutment surface 62s on the lower side of the positioning recess 62 of the second substrate 60 is pressed against the abutment surface 94s on the lower side of the protrusion 94 of the heat sink 80. That is, the force F2 along the second mounting surface 91 among the elastic forces F of the support plate 30 is a force pressing the second board 60 against the abutment surface 94s on the lower side of the projection 94, and thus the second board 60 is pressed against the abutment surface 94s on the lower side of the projection 94, and the second board 60 is suppressed from being displaced along the second mounting surface 91 to the opposite side of the pressing direction with respect to the abutment surface 94 s.

In the present embodiment, as described above, the two contact portions 31b are located on the opposite side of the second light-emitting element 63 side from the positioning recess 62 of the second substrate 60, and the protrusion 94 enters the positioning recess 62. That is, in a plan view of the second base plate 60, the lower abutment surface 94s of the protrusion 94 is positioned in the direction of the force F2 that presses the second base plate 60 against the lower abutment surface 94s of the protrusion 94 by the support plate 30 with respect to the contact portion 31 b. In the present embodiment, as shown in fig. 7, when the second board is viewed in plan, the two contact portions 31b overlap each other in a direction perpendicular to a direction of a force F2 in which the support plate 30 presses the second board 60 against the contact surface 94 s. One of the contact portions 31b corresponds to one of the protrusions 94, and the other contact portion 31b corresponds to the other protrusion 94. More specifically, as shown in fig. 19, when the second substrate 60 is viewed in plan, at least a part of the lower abutment surface 94s of one of the projections 94 is located between the straight line La and the straight line Lb. The straight line La is a straight line parallel to the direction of the force F2 in which the support plate 30 presses the second substrate 60 against the contact surface 94s in a plan view of the second substrate 60 and passing through one end of the one contact portion 31b in the direction perpendicular to the direction. The straight line Lb is parallel to the straight line La and passes through the other end of one of the contact portions 31 b. As shown in fig. 7, when the second substrate 60 is viewed in plan, at least a portion of the lower abutment surface 94s of the other protrusion 94 is located between the straight line Lc and the straight line Ld. Here, the positional relationship between the two protrusions 94 and the second base plate 60 shown by the broken lines in fig. 7 is a positional relationship in a state where the second base plate 60 is fixed to the heat sink 80 by the elastic force of the support plate 30. The straight line Lc is a straight line parallel to the direction of the force F2 with which the support plate 30 presses the second board 60 against the contact surface 94s in a plan view of the second board 60 and passing through one end of the other contact portion 31b in the direction perpendicular to the direction. The straight line Ld is a straight line parallel to the straight line Lc and passing through the other end of the other contact portion 31 b.

Further, a straight line La passing through one contact portion 31b is positioned on the opposite side to the other contact portion 31b side. The straight line Lc in the other contact portion 31b is located on the opposite side to the one contact portion 31b side. The straight line La and the straight line Lc are parallel to the direction of the force F2 in which the support plate 30 presses the second substrate 60 against the contact surface 94s when the second substrate 60 is viewed in plan. Therefore, the straight line La is also a straight line which is parallel to the direction of the force F2 in which the support plate 30 presses the second substrate 60 against the contact surface 94s and which passes through the end of the one contact portion 31b on the side opposite to the other contact portion 31b side in a plan view of the second substrate 60. The straight line Lc is also a straight line parallel to the straight line La and passing through the end of the other contact portion 31b opposite to the one contact portion 31 b. At least a part of the lower abutment surface 94s of one projection 94 and at least a part of the lower abutment surface 94s of the other projection 94 are located between the straight line La and the straight line Lc.

A straight line Lb passing through one of the contact portions 31b is located on the other contact portion 31b side, and a straight line Ld in the other contact portion 31b is located on the one contact portion 31b side. The straight line Lb and the straight line Ld are parallel to the direction of the force F2 in which the support plate 30 presses the second substrate 60 against the contact surface 94s when the second substrate 60 is viewed in plan. Therefore, the straight line Lb is also a straight line which is parallel to the direction of the force F2 in which the support plate 30 presses the second substrate 60 against the contact surface 94s and which passes through the end portion of the one contact portion 31b on the other contact portion 31b side in a plan view of the second substrate 60. The straight line Ld is also a straight line parallel to the straight line Lb and passing through the end portion of one of the other contact portions 31b on the contact portion 31b side. The center of gravity 60G of the second substrate 60 is located between the straight line Lb and the straight line Ld. Therefore, the center of gravity 60G of the second substrate 60 is also located between the straight line La and the straight line Lc.

In the present embodiment, as described above, since the grease 24 as a flow member is applied to the surface of the second substrate 60 opposite to the side on which the second light-emitting element 63 is mounted, the grease 24 is sandwiched between the second substrate 60 and the second mounting surface 91 as shown in fig. 16 and 20. Therefore, when the second substrate 60 is pressed against the second mounting surface 91, a part of the grease 24 may be pushed out from between the second substrate 60 and the second mounting surface 91. As described above, the second mounting surface 91 is an end surface of the base 95 protruding forward from the front surface 83f of the second bottom plate 83, and the outer edge of the second mounting surface 91 is surrounded by the outer edge of the second substrate 60. Therefore, the excess grease 24 pushed out from between the second substrate 60 and the second mounting surface 91 is pushed out onto the front surface 83f of the second bottom plate 83 around the base 95. Therefore, the adhesion of a part of the excess grease 24 to the mounting surface 60s of the second substrate 60 on which the second light-emitting element 63 is mounted is suppressed, and the adhesion of the excess grease 24 to the second light-emitting element 63 is suppressed. Further, the flow member is not limited to grease. The flow member is not limited to a member having fluidity at all times as long as it has fluidity at least when the first substrate 50 is placed on the first placement surface 86 and when the second substrate 60 is placed on the second placement surface 91. Therefore, the fluid members include uncured fluid members such as grease and adhesive which are not cured even after the first and second substrates 50 and 60 are placed on the placement surfaces 86 and 91, and cured fluid members such as adhesive made of thermosetting resin which can be cured after the first and second substrates 50 and 60 are placed on the placement surfaces, as shown in the present embodiment. The flow member sandwiched between the first substrate 50 and the first mounting surface 86 and the flow member sandwiched between the second substrate 60 and the second mounting surface 91 may be the same or different members.

As described above, the flow member recess 96 is formed between the outer peripheral surface of the lower side of the base 90 and the front surface 83f of the second bottom plate 83 on the upper side of the base 95 in the heat sink 80. An outer edge 86e of the outer edge of the first mounting surface 86 on the second mounting surface 91 side is substantially parallel to an outer edge 91e of the outer edge of the second mounting surface 91 on the first mounting surface 86 side, and extends in the left-right direction. The outer edge of the first mounting surface 86 is surrounded by the outer edge of the first substrate 50, and the outer edge of the second mounting surface 91 is surrounded by the outer edge of the second substrate 60. Therefore, an outer edge 86e of the outer edge of the first mounting surface 86 on the second mounting surface 91 side is an edge of the first mounting surface 86 on the second substrate 60 side in the region overlapping the first substrate 50. An outer edge 91e of the outer edge of the second mounting surface 91 on the first mounting surface 86 side is an edge of the second mounting surface 91 on the first substrate 50 side in the region overlapping the second substrate 60. That is, the flow member recess 96 is formed between the edge portion on the second substrate 60 side of the region overlapping with the first substrate 50 in the first mounting surface 86 and the edge portion on the first substrate 50 side of the region overlapping with the second substrate 60 in the second mounting surface 91. Therefore, a part of the grease 24 toward the second board 60 side of the excess grease 24 pushed out from between the first board 50 and the first mounting surface 86 can be accommodated in the flow member recess 96. Further, a part of the grease 24 toward the first board 50 out of the excess grease 24 pushed out from between the second board 60 and the second mounting surface 91 can be accommodated in the flow member recess 96. That is, a part of the excess grease 24 accumulated between the first substrate 50 and the second substrate 60 can be accommodated in the flow member recess 96.

As described above, the outer edge 86e of the outer edge of the first mounting surface 86, which is positioned at the lower end on the second mounting surface 91 side, is substantially parallel to the outer edge 91e of the outer edge of the second mounting surface 91, which is positioned at the upper end on the first mounting surface 86 side, and extends in the left-right direction. Therefore, the region sandwiched between the outer edge 86e and the outer edge 91e is a region in which the distance between the edge of the first mounting surface 86 on the second substrate 60 side in the region overlapping the first substrate 50 and the edge of the second mounting surface 91 on the first substrate 50 side in the region overlapping the second substrate 60 is the smallest. At least a portion of the flow member recess 96 is located in this region.

As shown in fig. 9, at least a part of the flow member recess 96 is located between a first straight line Lf passing through one end of the first light emitting element 55 of the first substrate 50 in the direction perpendicular to the direction from the first substrate 50 side toward the second substrate 60 side and parallel to the direction from the first substrate 50 side toward the second substrate 60 side, and a second straight line Ls passing through the other end and parallel to the first straight line Lf. That is, at least a part of the flow member recess 96 is located between a first straight line Lf passing through one end of the first light emitting element 55 in the left-right direction and parallel to the up-down direction and a second straight line Ls passing through the other end and parallel to the first straight line Lf. Although not illustrated, at least a part of the flow member recess 96 is located between a straight line that passes through one end of the second light emitting element 63 of the second substrate 60 in the direction perpendicular to the direction from the first substrate 50 side toward the second substrate 60 side and is parallel to the direction from the first substrate 50 side toward the second substrate 60 side, and another straight line that passes through the other end and is parallel to the straight line. That is, at least a part of the flow member recess 96 is located between a straight line passing through one end of the second light emitting element 63 in the left-right direction and parallel to the up-down direction and another straight line passing through the other end and parallel to the straight line.

Next, the projection lens 20 will be explained.

The projection lens 20 shown in fig. 1 to 4 is a plano-convex lens and is disposed in front of the light source unit LU. The first light and the second light emitted from the light source unit LU enter the projection lens 20 from a flat incident surface on the rear surface side of the projection lens 20 and pass through the projection lens 20. The projection lens 20 has a flange 21 on the outer periphery. Examples of the material for forming the projection lens 20 include resin and glass.

Next, the lens holder 25 will be explained.

The lens holder 25 shown in fig. 1 to 4 is disposed between the heat sink 80 and the projection lens 20. The projection lens 20 is fixed to a lens holder 25. By fixing the lens holder 25 to the heat sink 80, the relative positions of the projection lens 20, the lens holder 25, and the heat sink 80 are fixed. As described above, the reflector unit 40, the support plate 30, the first substrate 50, and the second substrate 60 are fixed to the heat sink 80. Accordingly, the relative positions of the reflector unit 40, the support plate 30, the first base plate 50, and the second base plate 60 with respect to the projection lens 20 and the lens holder 25 are also fixed.

The lens holder 25 has a cylindrical holding portion 26 and a leg portion 27. The lens holder 25 is formed of, for example, resin, and the holding portion 26 and the leg portion 27 are integrally formed. The holding portion 26 extends from the projection lens 20 side to the heat sink 80 side. The flange 21 of the projection lens 20 is fixed to the end of the holding portion 26 on the projection lens 20 side. The leg portion 27 extends from the end of the holding portion 26 on the heat sink 80 side toward the heat sink 80 side. In the present embodiment, the lens holder 25 has three leg portions 27. The two legs 27 are arranged side by side in the left-right direction, and the other leg 27 is arranged above the two legs 27 arranged side by side. Flange portions 28 are formed at respective ends of the three leg portions 27 on the radiator 80 side, and the flange portions 28 are fixed to the radiator 80 by screws 29.

Of the three legs 27 fixed to the heat sink 80 in this manner, the two juxtaposed legs 27 sandwich the pair of first light-shielding portions 33 of the support plate 30. Further, as described above, since the pair of first light-shielding portions 33 are respectively connected to the fixing portions 32 connected to the ends of the base portion 31 of the support plate 30 in the left-right direction, the pair of first light-shielding portions 33 are arranged in parallel in the left-right direction. Therefore, the first light shielding portion 33 is positioned between the projection lens 20 and one of the two leg portions 27 arranged in parallel, and the second light shielding portion 33 is positioned between the projection lens 20 and the other leg portion 27. By providing such a first light-shielding portion 33, at least a part of the sunlight that has entered through the projection lens 20 is irradiated to the first light-shielding portion 33 without being irradiated to the leg portion 27 of the lens holder 25. Therefore, damage of the lens holder 25 by sunlight is suppressed.

As described above, the upper wall portion 34a of the second light shielding portion 34 of the support plate 30 is disposed above the connector 64 and extends substantially parallel to the base portion 31. Therefore, the upper wall portion 34a of the second light shielding portion 34 is located between the connector 64 and the projection lens 20. By providing such a second light shielding portion 34, at least a part of the sunlight that has entered through the projection lens 20 is irradiated onto the upper wall portion 34a of the second light shielding portion 34 without being irradiated onto the connector 64. Therefore, damage of the connector 64 due to sunlight is suppressed. In addition, it is difficult to visually recognize the connector 64 through the projection lens 20, and the design of the lamp unit can be improved.

Next, the emission of light from the vehicle headlamp 1 of the present embodiment will be described.

Fig. 21 is a schematic cross-sectional view of the lamp unit, schematically showing an example of an optical path of light emitted from the first light-emitting element and the second light-emitting element. In fig. 21, the heat sink 80, the fan 81, and the like are not shown. Further, the angle of each reflecting surface, the reflection angle of light, the refraction angle, and the like may be inaccurate. As described above, the vehicle headlamp is symmetrical in the left and right of the vehicle. In the following description of the light distribution, the light distribution in the case where the vehicle headlamps provided on the left and right are turned on or off similarly will be described.

As shown in fig. 21, a part of the first light L1 emitted from the first light-emitting element 55 directly enters the projection lens 20, and the other part of the first light L1 is reflected by one of the first reflection surface 43a of the light-shielding portion 43 and the third reflection surface 41r of the reflector 41 and enters the projection lens 20. By forming the distal end 43c of the light shielding portion 43as described above, the first light L1 passing through the vicinity of the distal end 43c of the light shielding portion 43 among the first light L1 incident on the projection lens 20 forms a cutoff line of the light distribution of the low beam. Although not illustrated, a part of the first light L1 emitted from the first light-emitting element 55 and diffused in the left-right direction is reflected by the first side reflector 41a and the second side reflector 41b and enters the projection lens 20. Further, a part of the first light L1 irradiated to the rear side of the front end 43c of the light shielding portion 43 is shielded by the light shielding portion 43. In addition, part of the first light L1 that is irradiated to the front side wall portion 35d of the third light shielding portion 35 of the support plate 30 is shielded by the front side wall portion 35 d. The low beam light distribution shown in fig. 22 (a) is formed by the first light L1 emitted from the first light emitting element 55 and incident on the projection lens 20 and emitted through the front cover 12. In addition, in (a) in fig. 22, S denotes a horizontal line.

Further, a part of the second light L2 emitted from the second light-emitting element 63 directly enters the projection lens 20, and the other part of the second light L2 is reflected by any one of the second reflecting surface 43b of the light-shielding portion 43 and the fourth reflecting surface 42r of the reflector 42 and enters the projection lens 20. Although not illustrated, a part of the second light L2 emitted from the second light-emitting element 63 and spreading in the left-right direction is reflected by the first and second side reflectors 42a and 42b and enters the projection lens 20. In addition, part of the second light L2 that strikes the front side wall portion 35d of the third light-shielding portion 35 of the support plate 30 is shielded by the front side wall portion 35 d. The light distribution formed by the second light L2 emitted from the second light emitting element 63 and incident on the projection lens 20 and emitted through the front cover 12 in this way is combined with the light distribution of the low beam to form the light distribution of the high beam shown in fig. 22 (B). In addition, in (B) in fig. 22, S denotes a horizontal line.

As described above, the vehicle headlamp 1 of the present embodiment includes the first light emitting element 55, the second light emitting element 63, the light shielding portion 43, and the projection lens 20. The light shielding portion 43 has a first reflection surface 43a on the upper surface and a second reflection surface 43b on the lower surface, and the front end 43c of the light shielding portion 43 has a step 43cs in the vertical direction corresponding to the shape of the cutoff line of the light distribution pattern of low beam. In the vehicle headlamp 1 of the present embodiment, a part of the first light and a part of the second light are directly transmitted through the projection lens 20. That is, a part of the first light and a part of the second light are incident on the projection lens 20 without being reflected, and pass through the projection lens 20. In this way, since it is assumed that a part of the first light and a part of the second light are directly incident on the projection lens 20, the vehicle headlamp 1 does not need a large reflector as described in the above patent document 1. Another part of the first light is reflected by the first reflecting surface 43a of the light shielding portion 43 disposed below the first light emitting element 55 and enters the projection lens 20, and another part of the second light is reflected by the second reflecting surface 43b of the light shielding portion 43 disposed above the second light emitting element 63 and enters the projection lens 20. Therefore, the first light and the second light can be effectively used. Further, in the vehicle headlamp 1, the cutoff line of the light distribution pattern of the low beam is formed by the front end 43c of the light shielding portion 43. As described above, in the vehicle headlamp 1, the first light and the second light can be efficiently incident on the projection lens 20 without using a large reflector, and the cutoff line of the light distribution of the low beam can be formed. Therefore, the vehicle headlamp 1 can be prevented from being enlarged.

In the vehicle headlamp 1 of the present embodiment, the plurality of first light-emitting elements 55 are provided in parallel in the left-right direction, and the plurality of first light-emitting elements 55a to 55c disposed on one side in the left-right direction and the plurality of first light-emitting elements 55e to 55g disposed on the other side are provided at different heights with respect to the specific first light-emitting element 55 d. When low beams are irradiated onto a vertical plane, the cutoff line of the light distribution pattern of the low beams is different from one side and the other side in the left-right direction in height with respect to a specific position. Therefore, the front end 43c of the light shielding portion 43 forming the cutoff line preferably has a height different from one side to the other side in the left-right direction with reference to a specific position. Here, by arranging the plurality of first light-emitting elements 55 at different heights as described above, the position of the emission surface of each first light-emitting element 55 can be easily matched with the height of the front end 43c of the light-shielding portion 43. Therefore, the first light emitted from each of the first light-emitting elements 55 easily reaches the vicinity of the tip 43c of the light-shielding portion 43, which forms the cutoff line of the light distribution pattern of the low beam, and the light intensity in the vicinity of the cutoff line can be increased in the light distribution pattern of the low beam.

In the vehicle headlamp 1 of the present embodiment, the average interval between the specific first light-emitting element 55d and the pair of first light-emitting elements 55c and 55e disposed so as to sandwich the specific first light-emitting element 55d is smaller than the average interval between the other plurality of first light-emitting elements 55a, 55b, 55f, and 55g adjacent to each other. By adjusting the average interval between the plurality of first light-emitting elements 55 in this manner, the average interval between the first light-emitting elements 55c to 55e arranged adjacent to each other in the vicinity of the center in the left-right direction can be made smaller than the average interval between the first light-emitting elements 55a to 55c and the first light-emitting elements 55e to 55g arranged adjacent to each other on both end sides in the left-right direction.

Therefore, compared to the case where the same number of first light-emitting elements are arranged at equal intervals, the light distribution pattern of the low beam is expanded in the left-right direction, and the vicinity of the center of the light distribution pattern of the low beam is made bright.

In the vehicle headlamp 1 according to the present embodiment, the first reflecting surface 43a on the upper surface of the light shielding portion 43 has the convex portion 43as corresponding to the light distribution pattern of the low beam. When the low beam is irradiated to the road surface, the light distribution pattern of the low beam is formed such that the irradiation ranges of the light are different from each other on one side and the other side in the left-right direction. That is, the low beam makes the irradiation ranges of light different between the opposite lane side and the opposite lane side. By providing the convex portion 43as on the first reflection surface 43a on the upper surface of the light shielding portion 43as described above, a desired low beam light distribution pattern in which the irradiation range of light is different between the left and right can be formed as described above.

In the vehicle headlamp 1 of the present embodiment, the specific first light-emitting element 55d and the step 43cs at the front end 43c of the light shielding portion 43 overlap each other in the vertical direction when viewed from the front. Further, the first light-emitting elements 55a to 55c disposed on one side in the left-right direction are provided at positions lower than the first light-emitting elements 55e to 55g disposed on the other side with reference to the specific first light-emitting element 55 d. Further, the front end 43c of the light shielding portion 43 is formed to be lower on one side in the left-right direction than on the other side with respect to the step 43 cs. By arranging the plurality of first light-emitting elements 55 and forming the distal end 43c of the light-shielding portion 43 in this manner, the plurality of first light-emitting elements 55 can be arranged along the shape of the distal end 43c of the light-shielding portion 43. Therefore, the first light emitted from each of the first light-emitting elements 55 can more easily reach the vicinity of the tip 43c of the light-shielding portion 43, which forms the cutoff line of the light distribution pattern of the low beam, and the light intensity in the vicinity of the cutoff line can be further increased in the light distribution pattern of the low beam.

In the vehicle headlamp 1 according to the present embodiment, the rear end 43d of the first reflecting surface 43a formed on the upper surface of the light blocking portion 43 has a step corresponding to the shape of the cutoff line of the light distribution pattern of the low beam. The front end 43c of the light shielding portion 43 and the rear end 43d of the first reflection surface 43a on the upper surface of the light shielding portion 43 have steps corresponding to the shape of the cutoff line of the light distribution of the low beam, respectively, thereby allowing the first light to more easily reach the vicinity of the front end 43c of the light shielding portion. Therefore, the light intensity in the vicinity of the cutoff line can be further increased in the light distribution pattern of the low beam.

In the vehicle headlamp 1 of the present embodiment, the step 43cs at the front end 43c of the light shielding portion 43 and the step 43ds at the rear end 43d of the first reflecting surface 43a overlap each other in the vertical direction when viewed from the front. By forming the light shielding portion 43 in this manner, the first light more easily reaches the vicinity of the tip 43c of the light shielding portion 43. Therefore, the light intensity in the vicinity of the cutoff line can be further increased in the light distribution pattern of the low beam.

The present invention has been described above by taking the embodiments as examples, but the present invention is not limited thereto.

For example, the number of the first light-emitting elements 55 is not particularly limited.

In the above-described embodiment, an example in which the plurality of first light-emitting elements 55 are arranged at two levels of height has been described. That is, an example in which the first light-emitting elements 55a to 55d are disposed at the same height and the first light-emitting elements 55e to 55g are disposed at the same height is described. However, the plurality of first light emitting elements 55 may be arranged in more stages of heights, or may be arranged in a column at the same height. The plurality of first light-emitting elements 55 are preferably arranged in a shape along the front end 43c of the light-shielding portion 43. The specific first light-emitting element is preferably disposed at a position overlapping with or higher than a straight line passing through the plurality of first light-emitting elements disposed at one side in the left-right direction with respect to the specific first light-emitting element, and at a position overlapping with or lower than a straight line passing through the plurality of first light-emitting elements disposed at the other side in the left-right direction. Therefore, the first light-emitting elements 55a to 55c may be arranged at the same height, the first light-emitting elements 55e to 55g may be arranged at the same height, and the specific first light-emitting element 55d may be arranged at an intermediate height between the first light-emitting elements 55a to 55c and the first light-emitting elements 55e to 55 g.

In the above embodiment, the example in which the intervals between the plurality of first light-emitting elements 55 are not uniform is described, but the plurality of first light-emitting elements 55 may be arranged at equal intervals.

In the above-described embodiment, the example in which the rear end 43d of the first reflection surface 43a on the upper surface of the light shielding portion 43 has the step 43ds corresponding to the shape of the cutoff line of the light distribution pattern of the low beam is described, but the step may not be formed at the rear end 43d of the first reflection surface 43 a.

Industrial applicability of the invention

According to the present invention, a vehicle headlamp capable of being used in the field of vehicle headlamps for automobiles and the like is provided, which can suppress the increase in size.

Claims (9)

1. A vehicle headlamp is characterized by comprising:

a first light emitting element that emits first light as low beam, a normal line of an emission surface of the first light being directed obliquely downward toward the front;

a second light emitting element which is disposed below the first light emitting element and emits second light having a normal line of an emission surface directed obliquely upward in the forward direction;

a light shielding portion extending forward from between the first light emitting element and the second light emitting element; and

a projection lens disposed in front of the light shielding portion and directly transmitting a part of the first light and a part of the second light,

the light shielding portion has a first reflection surface on an upper surface thereof, which reflects another portion of the first light, so that the another portion of the first light transmits through the projection lens, and a second reflection surface on a lower surface thereof, which reflects another portion of the second light, so that the another portion of the second light transmits through the projection lens,

the first reflecting surface is a reflecting surface extending forward from the first light emitting element side and recessed downward in a vertical plane parallel to the front-rear direction,

the front end of the light shielding part is provided with a step in the vertical direction corresponding to the shape of a cut-off line of the light distribution pattern of the low beam.

2. The vehicular headlamp according to claim 1,

the first light emitting element is provided in plurality in parallel in the left-right direction,

the plurality of first light-emitting elements arranged on one side in the left-right direction with respect to a specific first light-emitting element are different from the plurality of first light-emitting elements arranged on the other side in the left-right direction in installation height.

3. The vehicular headlamp according to claim 2,

an average interval between the specific first light-emitting element and a pair of the first light-emitting elements configured to sandwich the specific first light-emitting element is smaller than an average interval between other plural first light-emitting elements adjacent to each other.

4. The vehicular headlamp according to claim 2,

the specific first light-emitting element and the step of the front end of the light-shielding portion overlap each other in the vertical direction when viewed from the front, the plurality of first light-emitting elements arranged on one side in the horizontal direction with respect to the specific first light-emitting element are provided at positions lower than the plurality of first light-emitting elements arranged on the other side, and the front end of the light-shielding portion is formed so that one side in the horizontal direction is lower than the other side with respect to the step.

5. The vehicular headlamp according to claim 3,

the specific first light-emitting element and the step of the front end of the light-shielding portion overlap each other in the vertical direction when viewed from the front, the plurality of first light-emitting elements arranged on one side in the horizontal direction with respect to the specific first light-emitting element are provided at positions lower than the plurality of first light-emitting elements arranged on the other side, and the front end of the light-shielding portion is formed so that one side in the horizontal direction is lower than the other side with respect to the step.

6. The vehicle headlamp according to any one of claims 1 to 5,

the front end of the light shielding part is gradually recessed backward from the left and right ends toward the center.

7. The vehicle headlamp according to any one of claims 1 to 5,

the first reflecting surface on the upper surface of the light shielding portion has a convex surface portion corresponding to a light distribution pattern of low beams.

8. The vehicle headlamp according to any one of claims 1 to 5,

the rear end of the first reflecting surface has a step corresponding to the shape of a cutoff line of the light distribution pattern of the low beam.

9. The vehicular headlamp according to claim 8,

the step at the front end of the light shielding portion and the step at the rear end of the first reflecting surface overlap each other in the vertical direction when viewed from the front.

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