CN112113181A - Lamp unit - Google Patents

Lamp unit Download PDF

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Publication number
CN112113181A
CN112113181A CN202010550512.0A CN202010550512A CN112113181A CN 112113181 A CN112113181 A CN 112113181A CN 202010550512 A CN202010550512 A CN 202010550512A CN 112113181 A CN112113181 A CN 112113181A
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CN
China
Prior art keywords
light
emitting element
light source
lamp unit
light emitting
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN202010550512.0A
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Chinese (zh)
Inventor
山本照亮
望月一磨
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Koito Manufacturing Co Ltd
Original Assignee
Koito Manufacturing Co Ltd
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Filing date
Publication date
Application filed by Koito Manufacturing Co Ltd filed Critical Koito Manufacturing Co Ltd
Publication of CN112113181A publication Critical patent/CN112113181A/en
Pending legal-status Critical Current

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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141Light emitting diodes [LED]
    • F21S41/147Light emitting diodes [LED] the main emission direction of the LED being angled to the optical axis of the illuminating device
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141Light emitting diodes [LED]
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60QARRANGEMENT OF SIGNALLING OR LIGHTING DEVICES, THE MOUNTING OR SUPPORTING THEREOF OR CIRCUITS THEREFOR, FOR VEHICLES IN GENERAL
    • B60Q1/00Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor
    • B60Q1/02Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor the devices being primarily intended to illuminate the way ahead or to illuminate other areas of way or environments
    • B60Q1/04Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor the devices being primarily intended to illuminate the way ahead or to illuminate other areas of way or environments the devices being headlights
    • B60Q1/14Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor the devices being primarily intended to illuminate the way ahead or to illuminate other areas of way or environments the devices being headlights having dimming means
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141Light emitting diodes [LED]
    • F21S41/151Light emitting diodes [LED] arranged in one or more lines
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/19Attachment of light sources or lamp holders
    • F21S41/192Details of lamp holders, terminals or connectors
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/25Projection lenses
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/25Projection lenses
    • F21S41/255Lenses with a front view of circular or truncated circular outline
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/29Attachment thereof
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/30Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by reflectors
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/30Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by reflectors
    • F21S41/32Optical layout thereof
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/40Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by screens, non-reflecting members, light-shielding members or fixed shades
    • F21S41/43Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by screens, non-reflecting members, light-shielding members or fixed shades characterised by the shape thereof
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S45/00Arrangements within vehicle lighting devices specially adapted for vehicle exteriors, for purposes other than emission or distribution of light
    • F21S45/40Cooling of lighting devices
    • F21S45/47Passive cooling, e.g. using fins, thermal conductive elements or openings
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/29Attachment thereof
    • F21S41/295Attachment thereof specially adapted to projection lenses
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21WINDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
    • F21W2107/00Use or application of lighting devices on or in particular types of vehicles
    • F21W2107/10Use or application of lighting devices on or in particular types of vehicles for land vehicles
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21YINDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00Light-generating elements of semiconductor light sources
    • F21Y2115/10Light-emitting diodes [LED]

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Optics & Photonics (AREA)
  • Mechanical Engineering (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Abstract

The invention provides a low-cost lamp unit which can perform illumination under near light distribution and adaptive high beam distribution by using one light source substrate. The lamp unit (1) is provided with a light source substrate (31) on which a plurality of light-emitting elements (34) are mounted, and a projection lens (6) that projects light emitted from the plurality of light-emitting elements (34). The light source substrate (31) is provided with a first surface area (31L) inclined forward and obliquely downward relative to the optical axis (Lx) of the projection lens (6), and a second surface area (31H) inclined forward and obliquely upward. The plurality of light-emitting elements (34) are provided with a first light-emitting element (34L) for first light distribution and a second light-emitting element (34H) for second light distribution, the first light-emitting element (34L) is mounted on the first surface area (31L), and the second light-emitting element (34H) is mounted on the second surface area (31H).

Description

Lamp unit
Technical Field
The present invention relates to a Lamp unit suitably used for a Head Lamp (Head Lamp) of an automobile.
Background
The head lamp of the automobile adopts a structure for switching the high beam light distribution and the low beam light distribution. Further, in order to prevent glare on other vehicles such as an oncoming vehicle and a leading vehicle and to improve visibility in front of the vehicle, a headlamp that illuminates with a High beam light distribution (hereinafter referred to as an adaptive High beam light distribution) of an adb (adaptive Driving beam) system or an ahs (adaptive High beam system) system that shields only an area where other vehicles exist in the High beam light distribution is provided.
As a lamp unit of a headlamp for adaptive high beam light distribution, there is a technology of patent document 1 proposed by the applicant of the present application. This technique employs, as a light source unit, a configuration in which a light emitting element for low beam light distribution and a light emitting element for high beam light distribution are vertically arranged with an optical axis of a projection lens interposed therebetween. That is, a light source substrate (hereinafter referred to as a Lo light source substrate) on which light-emitting elements for low beam light distribution are mounted and a light source substrate (hereinafter referred to as a Hi light source substrate) on which light-emitting elements for adaptive high beam light distribution are mounted are arranged so as to face each other at a predetermined angle. A reflector having a portion called a shaper (shaper) for forming a light distribution pattern is disposed between the two light source substrates. Light emitted from the light emitting elements of the light source substrates is reflected by the shapers, and the reflected light is projected by the projection lens, whereby illumination under the near-beam light distribution and the adaptive high-beam light distribution is performed.
Documents of the prior art
Patent document
Patent document 1 Japanese patent laid-open publication No. 2018-116869
Disclosure of Invention
Problems to be solved by the invention
In the technique of patent document 1, in order to realize the near light distribution and the adaptive high light distribution by one lamp unit, the Lo light source substrate and the Hi light source substrate are configured as separate substrates and are mounted on the heat sink constituted by the unit body of the lamp unit separately. In order to supply power to the light emitting elements of the two light source substrates, the two light source substrates are connected to each other through an FPC (flexible wiring board), and a connector for connection to an in-vehicle power supply is mounted on each light source substrate.
The technique of patent document 1 requires two light source substrates, and further requires an FPC for electrically connecting these light source substrates and a connector provided for each light source substrate. Therefore, the number of components increases, and the component cost and the assembly cost increase. In addition, a work for accurately positioning each of the two light source substrates with respect to the heat sink is required, and thus, manufacturing of the lamp unit becomes difficult.
The invention aims to provide a lamp unit which can perform illumination under different light distribution by using a light source substrate, for example, illumination under near light distribution and adaptive high light distribution, has simple structure and low cost.
Means for solving the problems
The present invention is a lamp unit including a light source substrate on which a plurality of light emitting elements are mounted, and a projection lens for projecting light emitted from the plurality of light emitting elements, wherein the light source substrate includes a single metal plate having a plurality of surface regions oriented in different angular directions with respect to an optical axis of the projection lens, and the plurality of light emitting elements are mounted on surfaces of the different surface regions.
In the present invention, the light source substrate includes, for example, a first surface region inclined obliquely forward and downward with respect to the optical axis of the projection lens, and a second surface region inclined obliquely forward and upward, the plurality of light emitting elements include a first light emitting element for the first light distribution and a second light emitting element for the second light distribution, the first light emitting element is mounted on the first surface region, and the second light emitting element is mounted on the second surface region.
Effects of the invention
According to the present invention, the light source section can be formed of one light source substrate, and an FPC for electrical connection is not required, so that the number of components can be reduced, the structure can be simplified, and the cost can be reduced.
Drawings
Fig. 1 is a schematic longitudinal sectional view of a headlamp provided with a lamp unit according to the present invention.
Fig. 2 is a partially exploded perspective view of the lamp unit of the first embodiment.
Fig. 3 is a perspective view of a schematic structure of the light source substrate.
Fig. 4 is an enlarged cross-sectional view of a part of the light source substrate.
Fig. 5 is an enlarged sectional view of a main portion of the light source section and the reflector.
Fig. 6 is a front view of the reflector and the light source unit as viewed from the front.
Fig. 7 is a light distribution pattern diagram of low beams and adaptive high beams.
Fig. 8 is a sectional view of a main portion of a light source unit according to a modification of the first embodiment.
Fig. 9 is a sectional view of a main portion of a light source unit according to another modification of the first embodiment.
Fig. 10 is an enlarged cross-sectional view of a main portion of a light source unit according to the second embodiment.
Description of the reference numerals
1: a lamp unit; 2: a unit main body (heat sink); 3: a light source unit; 4: a reflector; 5: a lens holder; 6: a projection lens; 21: a heat sink; 22: a front surface; 31: a light source substrate; 31L: lo face region (first face region); 31H, 31H: a Hi face region (second face region); 32: a metal plate; 33: a wiring layer; 34: a light emitting element; 34L: an LED (first light emitting element) for Lo; 34H, a reaction pressure of: hi LED (second light emitting element) 35: a connector; HL: a head lamp.
Detailed Description
Next, embodiments of the present invention will be described with reference to the drawings. Fig. 1 is a schematic longitudinal cross-sectional view of an AHS headlamp for an automobile to which a lamp unit according to the present invention is applied. The lamp unit 1 is built in a lamp housing 100 of a headlamp HL mounted on the left and right front portions of a vehicle body of an automobile. The lamp housing 100 is composed of a lamp body 101 and a light-transmitting cover 102. The lamp unit 1 switches illumination under the low beam distribution and the adaptive high beam distribution when turned on. The lamp units of the left and right headlamps are basically the same in structure.
(first embodiment)
Fig. 2 is a partially exploded perspective view of the lamp unit 1 of the first embodiment. In fig. 1 and 2, the lamp unit 1 includes a unit body 2 configured as a heat sink, and the light source unit 3 and the reflector 4 are disposed on a front surface 22 of the unit body 2, that is, a surface facing the front of the lamp unit 1. A lens holder 5 is coupled to the front surface side of the unit main body 2, and a projection lens 6 is supported by the lens holder 5.
The unit body 2 is formed of a material having high thermal conductivity such as metal or highly thermally conductive resin, and the front surface 22 thereof is formed in a tapered shape whose longitudinal sectional shape is recessed in a triangular shape toward the rear of the lamp unit. The front surface 22 is defined by a horizontal ridge portion 22t set at a substantially center in the vertical direction of the unit main body, and includes an upper surface 22u extending in a region above the ridge portion 22t and inclined downward, and a lower surface 22d extending in a region below the ridge portion 22t and inclined upward. In the following, the vertical direction is based on fig. 1.
A plurality of heat radiating fins 21 constituting a heat sink are formed on the rear surface of the unit main body 2, and heat conducted from the light source unit 3 to the unit main body 2 is radiated from the heat radiating fins 21. A heat radiation fan may be built in the unit main body 2.
The light source unit 3 is mainly composed of one light source substrate 31. Fig. 3 is a schematic perspective view of the light source substrate 31, and fig. 4 is an enlarged cross-sectional view of a part thereof. The light source substrate 31 includes a metal plate 32 made of copper (Cu) or the like, and a wiring layer 33 formed on a surface of the metal plate. A light emitting element 34 as a light source and a connector 35 are mounted on the surface of the wiring layer 33.
The wiring layer 33 has an insulating layer 36 formed on the surface of the metal plate 32, and a conductive pattern 37 formed by selectively printing or etching a conductive layer is disposed on the surface of the insulating layer 36. A resist layer 38 is formed as a protective film so as to cover a desired portion of the conductive pattern 37, particularly a portion excluding a region where the light emitting element 34 and the connector 35 are mounted.
The metal plate 32 is formed of a substantially rectangular flat plate having a desired longitudinal and lateral dimension, and is bent at a ridge line in the horizontal direction set at a substantially center in the vertical direction thereof at a desired angle into a triangular roof shape protruding in the back direction. The angle of the curved bent portion 31t is equal to the angle formed by the upper surface portion 22u and the lower surface portion 22d of the front surface 22 of the unit body 2. Thus, the light source substrate 31 formed of the metal plate 32 is divided into an upper Lo surface region 31L and a lower Hi surface region 31H with the bent portion 31t as a boundary.
A plurality of light emitting elements 34 and connectors 35 are mounted on the surface of the wiring layer 33, and the light emitting elements 34 and the connectors 35 are electrically connected to each other through the wiring layer 33. As shown in fig. 3, the light emitting element 34 is composed of a plurality of LEDs (light emitting diodes), and a plurality of (here, seven) Lo LEDs 34L that emit low beams are mounted on the Lo surface region 31L of the light source substrate 31, and a plurality of (here, twelve) Hi LEDs 34H that emit high beams are mounted on the Hi surface region 31H. These Lo are lined up in the horizontal direction at a desired interval by the LED34L and Hi by the LED 34H. The light emitting surface of Lo LED34L is parallel to the surface of Lo surface region 31L, and the light emitting surface of Hi LED34H is parallel to the surface of Hi surface region 31H.
Two connectors 35 are provided, and one connector 35L mounted on the Lo surface region 31L of the light source substrate 31 is connected in series to the Lo LED 34L. The other connector 35H mounted on the Hi surface region 31H of the light source substrate 31 is connected in parallel to the Hi LED 34H.
The Lo LED34L and the Hi LED34H are controlled to emit light by a lighting control circuit formed on the light source substrate 31. The Lo LED34L is configured such that all LEDs are simultaneously controlled to emit light, but the Hi LED34H is configured such that each LED is independently controlled to emit light to achieve adaptive high beam distribution.
The light source substrate 31 is attached to the front surface 22 of the unit body 2 by fixing members such as screws, not shown, through holes 39 opened at a plurality of portions thereof. At this time, the curved portion 31t of the light source substrate 31 is positioned at the ridge line portion 22t of the tapered front surface 22 of the unit body 2, whereby the back surface of the light source substrate 31, that is, the back surface of the metal plate 32 is in close contact with the front surface 22 of the unit body 2. Since the bending angle of the light source substrate 31 is equal to the taper angle of the front surface 22, the bent portion 31t of the light source substrate 31 and the ridge portion 22t of the front surface 22 of the unit main body 2 are engaged so as to contact each other, and thus both are positioned.
Further, since the positioning accuracy of the light source substrate 31 in the left-right direction can be reduced compared to the positioning in the up-down direction, for example, the hole 39 may be formed as a long hole that is long in the up-down direction, so that the degree of freedom in the positioning in the up-down direction is obtained while the degree of freedom in the positioning in the left-right direction is restricted. At the same time, the inclination of the light source substrate 31 in the left-right direction can be matched with the front surface 22.
Since the light source substrate 31 after mounting has the upper Lo surface region 31L directed obliquely downward forward and the lower Hi surface region 31H directed obliquely upward forward, the light emitting surface of the Lo LED34L mounted in these regions is directed obliquely downward forward and the light emitting surface of the Hi LED34H is directed obliquely upward forward. That is, the light emitting surfaces of the LEDs 34L, 34H are oriented in different angular directions in the vertical direction with respect to the optical axis Lx.
The reflector 4 is supported by the unit body 2 at a position forward of the light source unit 3. Fig. 5 is a longitudinal sectional view of main parts of the light source unit 3 and the reflector 4, and fig. 6 is a front view of the light source unit and the reflector as viewed from the front. The reflector 4 includes an upper frame 41, a lower frame 42, a left frame 43, and a right frame 44 disposed so as to surround a region where the Lo LED34L and the Hi LED34H are disposed, and an intermediate frame 45 extending in the horizontal direction at a substantially middle position in the vertical direction and having both ends connected to the left frame 43 and the right frame 44, and is formed in a rectangular frame shape as a whole. Thus, the openings formed in the upper, lower, left, and right frames are vertically divided by the middle frame 45, and the Lo opening 46L is formed on the upper side and the Hi opening 46H is formed on the lower side.
An upper reflecting surface Ru and a lower reflecting surface Rd are formed on the surfaces of the upper frame 41 and the lower frame 42 facing the inside of the frames, respectively. Further, a left side reflecting surface Rl and a right side reflecting surface Rr are formed on the surfaces of the left frame 43 and the right frame 44 facing the inside of the frames, respectively. Further, a middle upper reflecting surface Rcu and a middle lower reflecting surface Rcd are formed on the upper surface and the lower surface of the middle frame 45, respectively. Since the middle frame functions to form a cut-off line (cutline) for low beam light distribution as described later, it will be referred to as a shaper hereinafter, and among them, the upper reflecting surface Rcu will be referred to as a shaper upper reflecting surface, and the middle lower reflecting surface Rcd will be referred to as a shaper lower reflecting surface.
In fig. 6, the areas of the reflecting surfaces are dotted for easy understanding. That is, the Lo opening 46L is surrounded by the upper regions of the left and right reflecting surfaces Rl and Rr, the upper reflecting surface Ru, and the shaper upper reflecting surface Rcu, and the Lo reflector portion as the first reflector portion is constituted by these reflecting surfaces. Similarly, the Hi opening 46H is surrounded by the lower regions of the left and right reflecting surfaces Rl and Rr, the lower reflecting surface Rd, and the shaper lower reflecting surface Rcd, and the Hi reflector portion as the second reflector portion is constituted by these reflecting surfaces.
The upper reflecting surface Ru, the lower reflecting surface Rd, the left reflecting surface Rl, and the right reflecting surface Rr are each formed by a concave curved surface having a gentle curvature. On the other hand, the shaper 45 has a vertical cross-sectional shape close to a triangle having a front edge 45e facing forward as a vertex, the shaper lower reflective surface Rcd is formed by a convex curved surface or a flat surface, and the shaper upper reflective surface Rcu is formed by a concave curved surface having a larger curvature than the shaper lower reflective surface Rcd.
The front edge portion 45e extends in the left-right direction of the reflector 4, but the height positions in the left-right direction are different from each other at a substantially central position in the extending direction, and the right side is slightly higher than the left side when viewed from the front of the reflector 4. Further, the front edge portion 45e continues in a state of being inclined upward to the right in a substantially central region.
As shown in fig. 5, the projection lens 6 is fixed to the unit body 2 by the lens holder 5 so that the focal point F on the rear side is located in the vicinity of the front edge portion 45e of the shaper 45. The light emitting surface of the Lo LED34L faces obliquely downward forward, but a normal line passing through the center of the light emitting surface faces the focal point F or its vicinity. Similarly, the light emitting surface of the Hi LED34H faces obliquely upward in the forward direction, and a normal line passing through the center of the light emitting surface faces approximately the focal point F.
In the lamp unit 1 having the above configuration, when the Lo LED34L and the Hi LED34H emit light, the light emitted from the LEDs 34L and 34H is reflected by the reflector 4 and projected to the front area of the automobile through the projection lens 6 to illuminate, as shown by the optical path of a part of the light rays in fig. 5.
When the Lo LED34L emits light, the emitted low beam is reflected by the Lo reflector. That is, it is reflected by the left and right reflecting surfaces Rl and Rr in the left-right direction. In the vertical direction, the light is reflected by the upper reflecting surface Ru and the shaper upper reflecting surface Rcu. These reflected lights enter the projection lens 6 and are projected by the projection lens 6 to the vicinity area in front of the automobile. Fig. 7 (a) shows a projected light distribution pattern in which a part of the projected light, particularly the light projected to the upper region, is blocked. The height of the front edge portion 45e of the shaper 45 is different between the left and right, thereby forming a low beam light distribution pattern PL having a cutoff line CL stepped in the horizontal direction at the upper edge. The dotted line in (a) in fig. 7 indicates the region corresponding to the seven Lo LEDs 34L.
When the Hi LED34H emits light, the emitted high beam is reflected by the Hi reflector. That is, it is reflected by the left and right reflecting surfaces Rl and Rr in the left-right direction. In the vertical direction, the light is reflected by the lower reflecting surface Rd and the shaper lower reflecting surface Rcd. These reflected lights are hardly restricted by the shaper 45, and as shown in fig. 7 (b), are illuminated by the projection lens 6 as the high beam light distribution PH in a distant area in front of the automobile to an area above the low beam light distribution PL.
Therefore, the low beam light distribution pattern PL is illuminated by emitting the Lo LED34L, and the adaptive high beam light distribution pattern APH is illuminated by synthesizing the high beam light distribution PH obtained by emitting the Hi LED34H on the low beam light distribution pattern PL. The broken line in (b) in fig. 7 indicates the region corresponding to the seven Lo LEDs 34L and the twelve Hi LEDs 34H.
Although not shown in the drawings, when illumination is performed by the adaptive high beam light distribution pattern, adaptive high beam light distribution illumination can be performed by selectively controlling the light emission of each Hi LED 34H. That is, by turning off or reducing the Hi LED34H that illuminates the area where the oncoming vehicle or the leading vehicle is present, it is possible to prevent dazzling of the oncoming vehicle or the leading vehicle due to the illumination of the area.
As described above, in the lamp unit of the first embodiment, the light source unit 3 is configured mainly from one light source substrate 31, and the light emitting elements 34L and 34H are mounted on the Lo surface region 31L and the Hi surface region 31H in which the light source substrate 31 is bent and inclined, respectively. Therefore, the light source unit can be easily configured such that the light emitting surface of the Lo LED34L faces a desired diagonally downward front direction and the light emitting surface of the Hi LED34H faces a desired diagonally upward front direction.
Thus, the light source unit 3 can be configured by one light source substrate 31, and an FPC for electrical connection is not required, so that the number of components can be reduced, and the component cost and the assembly cost can be reduced. Further, compared to a configuration in which two light source substrates are disposed to face each other at different angles as in patent document 1, the number of positioning steps in assembling the light source substrates to the lamp unit can be reduced, and manufacturing becomes easy.
In the first embodiment, in order to improve the accuracy of positioning of the light source substrate 31 with respect to the unit main body, the first positioning portion may be formed on the light source substrate 31. For example, as shown in a partial cross-sectional view in fig. 8, a concave groove 301 extending in the left-right direction (left-right direction when viewed from the front of the lamp unit, the same applies hereinafter) along the bent portion 31t is formed on the back surface of the metal plate 32 of the light source substrate 31. The groove 301 can be easily formed in a press working when bending the metal plate 31. In response to this, as the second positioning portion, a convex line 201 extending in the horizontal direction along the ridge line portion 22t is formed on the front surface 22 of the unit main body 2.
According to this configuration, when the light source substrate 31 is attached to the unit main body 2, the first positioning portion and the second positioning portion, that is, the concave groove 301 of the metal plate and the convex strip 201 of the unit main body 2 are fitted to each other to perform positioning. By setting the lengths of the concave groove 301 and the convex strip 201 in the left-right direction to the corresponding dimensions, the light source substrate 31 and the unit main body 2 can be positioned in the left-right direction when they are fitted.
Alternatively, as shown in fig. 9, the bent portion 31t of the light source substrate 31 is bent into a trapezoidal cross-sectional shape, and one or more positioning holes 302 are formed as first positioning portions on the top surface of the bent portion 31t in the left-right direction. Correspondingly, the ridge portion 22t of the front surface 22 of the unit main body 2 is formed as a flat surface, and one or more positioning protrusions 202 are formed as second positioning portions in a horizontal direction on this flat surface.
According to this configuration, when the light source substrate 31 is attached to the unit main body 2, the positioning hole 302 is fitted to the positioning protrusion 202, whereby the light source substrate 31 and the unit main body 2 can be positioned. In this configuration, the light source substrate 31 can be positioned in both the vertical direction and the horizontal direction.
(second embodiment)
Fig. 10 is a sectional view of the light source unit 3 in the second embodiment. Since the wiring layer 33 is formed on the surface of the bent metal plate 32 in the light source substrate 31 of the first embodiment, the manufacturing process may become complicated as compared with a structure in which a wiring layer is formed on the surface of a flat metal plate. Further, since the wiring layer 33 includes the insulating layer 36 and the LED34 is mounted on the surface thereof, the heat conduction efficiency when the heat generated in the LED34 is conducted to the metal plate 32 is not necessarily high due to the heat insulating effect of the insulating layer 36, and there is room for improvement in terms of cooling of the LED 34.
The structure of the metal plate 32 of the light source substrate 31A of the second embodiment is the same as that of the first embodiment. On the other hand, the LED34 is mounted on the surface of the metal plate 32 via the mount 311. A separate wiring board, for example, a circuit board 312 using glass epoxy resin is mounted on the other part of the surface of the metal plate 32. Although not shown, the connector 35 is mounted on the circuit board 312. In addition, the base 311 is electrically connected to the circuit board 312 via bonding wires 313.
According to this structure, a process of forming a wiring layer on the surface of the bent metal plate is not required. On the other hand, since the light source substrate 31A can be manufactured by the step of mounting the base 311 on which the LED34 is mounted on the surface of the bent metal plate 32 and the step of mounting the circuit board 312 on which the connector 35 is mounted on the surface of the metal plate 32, the manufacturing process can be simplified.
Further, since the wiring layer 33 having the insulating layer 36 as in the first embodiment does not exist between the LED34 and the metal plate 32, and the base 311 made of a material having high thermal conductivity can be used, heat generated in the LED34 can be efficiently conducted from the base 311 to the metal plate 32, and the cooling effect of the LED34 can be improved.
Needless to say, illumination under the low beam light distribution pattern and the adaptive high beam light distribution pattern can also be performed in the second embodiment. Further, since the light source unit 3 can be configured by one light source substrate 31A, the structure of the lamp unit 1 can be simplified and the cost can be reduced, which is also the same as the first embodiment.
Although the first and second embodiments have been described with respect to the example in which the present invention is applied to the AHS headlamp, the lamp unit of the present invention can be applied to any vehicle lamp such as a headlamp that can switch between low beam light distribution and high beam light distribution. Alternatively, the present invention can also be applied to a vehicle lamp that can switch different light distributions.
The configurations of the unit body, the reflector, and the projection lens constituting the lamp unit are not limited to those described in the embodiments.

Claims (10)

1. A lamp unit including a light source substrate on which a plurality of light emitting elements are mounted, and a projection lens for projecting light emitted from the plurality of light emitting elements,
the light source substrate includes a single metal plate having a plurality of surface regions oriented in different angular directions with respect to an optical axis of the projection lens, and the plurality of light emitting elements are mounted on surfaces of the different surface regions.
2. The lamp unit according to claim 1, wherein the light source substrate includes a first surface region inclined obliquely forward and downward with respect to an optical axis of the projection lens, and a second surface region inclined obliquely forward and upward, the plurality of light emitting elements include a first light emitting element for first light distribution and a second light emitting element for second light distribution, the first light emitting element is mounted on the first surface region, and the second light emitting element is mounted on the second surface region.
3. The lamp unit according to claim 1 or 2, wherein the light source substrate is fixedly supported by a unit main body of the lamp unit as a heat sink, and is in contact with the unit main body on a back surface of the metal plate.
4. The lamp unit according to claim 3, wherein the light source substrate includes a wiring layer formed on a surface of the metal plate, and the plurality of light emitting elements are mounted on the surface of the wiring layer.
5. The lamp unit according to claim 3, wherein the light source substrate includes a base having the light emitting element mounted on a surface of the metal plate, and a circuit wiring board mounted on the surface of the metal plate and electrically connected to the light emitting element.
6. The lamp unit according to claim 4 or 5, wherein a first positioning portion is formed in a part of the metal plate, and a second positioning portion that engages with the first positioning portion to position the metal plate is formed in the unit main body.
7. The lamp unit according to claim 6, wherein the first positioning portion is a groove or a hole formed in the back surface of the metal plate, and the second positioning portion is a rib or a protrusion fitted into the groove or the hole.
8. The lamp unit according to claim 2, wherein the first light-emitting element is a light-emitting element that performs illumination in low beam light distribution, and the second light-emitting element is a light-emitting element that performs illumination in high beam light distribution.
9. The lamp unit according to claim 8, wherein the second light emitting element is configured as a plurality of light emitting element groups each of which is independently controlled to emit light.
10. The lamp unit according to claim 8 or 9, wherein a reflector is provided between the light source unit and the projection lens, and the reflector is formed integrally with a first reflector unit that reflects light of the first light-emitting element and a second reflector unit that reflects light of the second light-emitting element.
CN202010550512.0A 2019-06-19 2020-06-16 Lamp unit Pending CN112113181A (en)

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