JP2013191447A - Optical unit - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a technology for simplifying a manufacturing process of an optical unit.SOLUTION: An optical unit is provided with: a shade to be displaced between an advanced position and a retreated position; a motor 150 which has a terminal connection part for supplying power and an output shaft 152 to be connected to the shade, and displaces the shade from one of the advanced position and the retreated position to the other by rotation of the output shaft 152; and a case 170 which has a wall part 172 for forming a housing space 174 of the motor 150, an opening part 176 for inserting the motor 150 into the housing space 174, a connector 178 to be connected to the outside power source, and power supply terminals 180A, 180B which are electrically connected to the connector 178 and are exposed in the housing space 174. The power supply terminals 180A, 180B are arranged in the housing space 174 so that the terminal connection part and the power feeding terminals 180A, 180B may be physically brought into contact with each other, when the motor 150 is inserted into the housing space 174.

Description

  The present invention relates to an optical unit, and more particularly to an optical unit used for a vehicular lamp.

  Conventionally, there is a variable-light-distribution type vehicle headlamp device that forms a low-beam light distribution pattern by shielding light from a light source with a shade and forms a high-beam light distribution pattern when not shaded by a shade. Further, along with the recent improvement in performance of vehicles, there has been proposed a vehicle headlamp device that forms a special light distribution pattern having a shape different from that of a standard low beam or high beam according to the surrounding conditions. . In particular, in the case of a high beam, it is necessary to consider glare for oncoming vehicles and pedestrians while improving the driver's visibility. Therefore, for example, the vehicular lamp disclosed in Patent Document 1 has a structure that can optimally set a high beam irradiation area according to the presence or absence of a pedestrian, a preceding vehicle, or an oncoming vehicle.

JP 2007-179969 A

  Under such circumstances, the present inventor has come to recognize the following problems. That is, as an optical unit that realizes switching of the above-described light distribution pattern in the vehicle lamp, for example, the optical unit is displaced between an advance position where a part of the light source light is shielded and a retreat position where the part of the light source light is not shielded. A configuration in which a plurality of possible shades are provided and the light distribution pattern is switched by switching the position of each shade is conceivable. Specifically, for example, the first shade is arranged at the light shielding position to form a low beam light distribution pattern, the second shade is arranged at the light shielding position, and the first shade is arranged at the non-light shielding position. A pattern is formed, and the first shade and the second shade are arranged at non-light-shielding positions to form a high beam light distribution pattern. It is conceivable to use a motor such as a DC motor for the displacement of the shade.

  There is always a need to simplify the manufacturing process of vehicular lamps. For this reason, the optical unit having the above-described configuration is naturally required to simplify the manufacturing process.

  This invention is made | formed in view of such a subject, The objective is to provide the technique for aiming at the simplification of the manufacturing process of an optical unit.

  In order to solve the above problems, an aspect of the present invention is an optical unit. The optical unit is an optical unit used in a vehicular lamp, a shade that can be displaced between an advancing position where a part of the light source light is shielded and a retreat position where the part of the light source light is not shielded; And a motor for displacing the shade from one of the advanced position and the retracted position by rotation of the output shaft, and a housing space for the motor. A wall portion to be formed, an opening for inserting the motor into the housing space, a connector connected to an external power source, and a case having a power feeding terminal electrically connected to the connector and exposed in the housing space. Prepare. The power feeding terminal is arranged in the housing space so that the terminal connection portion and the power feeding terminal are in physical contact when the motor is inserted into the housing space.

  According to this aspect, the electrical connection between the motor and the connector can be performed at the same time, so that the manufacturing process of the optical unit can be simplified.

  In the above aspect, a first wall portion in contact with the opening portion of the wall portions is divided into a first portion and a second portion by a slit extending from the opening portion, and the case includes the first portion and the first portion. The second part is displaced in a direction away from each other to allow the motor to enter the accommodation space, and when the motor is accommodated in the accommodation space, the first part and the second part are displaced. Displacement from the position toward each other may be suppressed to prevent the motor from being separated from the accommodation space. Thereby, the manufacturing process of an optical unit can be simplified more.

  In the above aspect, a base portion that holds the shade is provided, the first wall portion abuts on the base portion, and the first portion includes a first flange portion that projects in a surface direction of the first wall portion. The second portion includes a second flange portion protruding in a surface direction of the first wall portion, and the case is fixed to the base portion in each of the first flange portion and the second flange portion. A fixing mechanism may be provided. Accordingly, it is possible to suppress the motor from dropping from the case by using a mechanism for attaching the case to the base portion.

  In any one of the above aspects, a base portion that holds the shade is provided, the first wall portion is in contact with the base portion, and the first portion and the second portion are respectively on surfaces that are in contact with the base portion. It has a positioning convex part, and the base part may have a fitting part into which the positioning convex part is fitted. Thereby, the fall of the motor from the case can be suppressed by using a positioning mechanism for the base portion of the case.

  ADVANTAGE OF THE INVENTION According to this invention, the technique for aiming at the simplification of the manufacturing process of an optical unit can be provided.

It is a vertical sectional view showing a schematic structure of a vehicular lamp in which a lamp unit having an optical unit according to an embodiment is mounted. It is a perspective view which shows schematic structure of a lamp unit. It is a disassembled perspective view of a lamp unit. It is a disassembled perspective view of the optical unit which concerns on embodiment. It is a perspective view which shows schematic structure of a motor and a case. It is a schematic sectional drawing of a motor and a case. FIGS. 7A and 7B are perspective views for explaining the connection between the motor and the power supply terminal. FIG. 8A to FIG. 8C are views for explaining the shape change of the first wall portion when the motor is accommodated in the case. FIG. 9A to FIG. 9C are diagrams for explaining the states of the first shade and the second shade and the light distribution pattern to be formed. FIG. 10A is an enlarged view of the vicinity of the gear portion of the first shade. FIG. 10B is an enlarged view of the vicinity of the gear portion of the second shade. It is a figure which shows schematic structure of the optical unit seen from the lamp back. FIG. 12A is an exploded perspective view showing a schematic structure of the motor. FIG. 12B is a schematic diagram of the internal structure of the motor.

  The present invention will be described below based on preferred embodiments with reference to the drawings. The same or equivalent components, members, and processes shown in the drawings are denoted by the same reference numerals, and repeated descriptions are omitted as appropriate. The embodiments do not limit the invention but are exemplifications, and all features and combinations thereof described in the embodiments are not necessarily essential to the invention.

  FIG. 1 is a vertical sectional view showing a schematic structure of a vehicular lamp in which a lamp unit having an optical unit according to an embodiment is mounted. FIG. 2 is a perspective view showing a schematic structure of the lamp unit. FIG. 3 is an exploded perspective view of the lamp unit. The vehicular lamp 1 described in the present embodiment is a vehicular headlamp apparatus having a pair of headlamp units arranged on the left and right sides in front of the vehicle. Since the pair of headlamp units has substantially the same configuration except that they have a symmetrical structure, FIG. 1 shows the structure of the headlamp unit arranged on the right side of the vehicle as the vehicle lamp 1.

  As shown in FIG. 1, the vehicular lamp 1 includes a lamp body 2 having an opening on the front side of the vehicle, and a translucent cover 4 attached so as to cover the opening of the lamp body 2. The translucent cover 4 is made of translucent resin or glass. A lamp unit 10 and a control unit 12 are accommodated in a lamp chamber 3 formed by the lamp body 2 and the translucent cover 4. A swivel shaft 14 serving as a swing center of the lamp unit 10 protrudes from the upper part of the lamp unit 10. The swivel shaft 14 is attached to the upper frame of the bracket 16 that is a substantially rectangular frame so as to be rotatable about the axis. The bracket 16 is fixed to the lamp body 2 by a support mechanism (not shown).

  A swivel actuator 18 is provided below the bracket 16. The swivel actuator 18 is provided with a rotation output shaft (not shown) protruding upward. The lamp unit 10 is disposed within the frame of the bracket 16, and the lower surface of the lamp unit 10 is connected to the rotation output shaft. The swivel actuator 18 is driven in accordance with, for example, a steering operation, so that the lamp unit 10 can swivel in the left-right direction around the swivel shaft 14.

  A control unit 12 that controls turning on / off of the lamp unit 10 and displacement of a shade to be described later is disposed below the lamp chamber 3. A power supply socket 20 for supplying power to the light source bulb of the lamp unit 10 is connected to the controller 12 via a cord 22. In addition, the position where the control part 12 is provided is not specifically limited.

  An extension member 24 is provided in the lamp chamber 3. The extension member 24 is disposed on the lamp front side of the lamp unit 10 and is fixed to the lamp body 2. The extension member 24 has an opening 24 a in the area where the lamp unit 10 exists, and covers the area between the front opening of the lamp body 2 and the lamp unit 10 when viewed from the front of the lamp.

  As shown in FIGS. 1 to 3, the lamp unit 10 includes a light source bulb 26, a bulb holding portion 28, a reflector portion 30, a lens holder 32, a projection lens 34, and an optical unit 100. The light source bulb 26 is, for example, an incandescent bulb, a halogen lamp, a discharge bulb, or the like. A power supply socket 20 is attached to the light source bulb 26. As a result, power can be supplied from the control unit 12 to the light source bulb 26. The light source may be a light emitting element.

  The bulb holding portion 28 is an annular member and has a cylindrical bulb insertion port (not shown) having the optical axis of the lamp unit 10 as a central axis. The reflector unit 30 has a reflecting surface (not shown) formed of a part of a spheroid. In addition, a cylindrical bulb insertion port (not shown) having the optical axis of the lamp unit 10 as the central axis is formed at the center of the rear part of the reflector unit 30. A flange portion 30 a having a main surface facing the front of the lamp and a main surface facing the rear of the lamp is provided on the periphery of the front opening 31 of the reflector portion 30. A plurality of positioning projections 30b projecting forward of the lamp are provided at predetermined positions on the front surface of the front side of the lamp 30a. Further, a plurality of through holes 30c are provided at predetermined positions of the flange portion 30a so as to penetrate the flange portion 30a in the lamp front-rear direction. A swivel shaft 14 is provided on the upper portion of the flange portion 30a.

  The valve holding portion 28 is arranged so that the central axis of the valve insertion port of the valve holding portion 28 and the central axis of the valve insertion port of the reflector portion 30 are located on the same straight line, and the valve insertion of the reflector portion 30 is performed. It is fixed at the mouth entrance. In the present embodiment, the valve holding portion 28 and the reflector portion 30 are integrally formed, but they may be separate. The light source bulb 26 is inserted into the bulb insertion port of the bulb holding unit 28 and the bulb insertion port of the reflector unit 30 from the rear of the lamp, and is detachably attached to the reflector unit 30. By the bulb holder 28, the light source bulb 26 is fixed at a position where the light emitting portion substantially coincides with the first focal point of the reflecting surface of the reflector portion 30.

  A lens holder 32 is disposed on the front side of the reflector unit 30 with the optical unit 100 interposed therebetween. The lens holder 32 includes a cylindrical portion 32a and a plurality of leg portions 32b protruding from the cylindrical portion 32a to the lamp rear side. Each leg portion 32b has a connection portion 32b1 formed with its tip folded back at a substantially right angle. Each connecting portion 32b1 is provided with a through hole 32c extending in the lamp front-rear direction. A projection lens 34 is fitted in the cylindrical portion 32a. The projection lens 34 is a plano-convex aspherical lens having a convex front surface and a flat rear surface. The projection lens 34 uses a light source image formed on the rear focal plane including the rear focal point as a reverse image and a virtual vertical position in front of the lamp. Project on the screen. The projection lens 34 is disposed on the optical axis of the lamp unit 10 by the lens holder 32 and at a position where the rear focal point substantially coincides with the second focal point of the reflecting surface of the reflector unit 30.

  The optical unit 100 includes a substantially plate-like base portion 110 disposed so that the main surface faces the lamp front-rear direction. The base part 110 has an annular frame part 112 as viewed from the front of the lamp, and a shade connecting part 114 extending in a substantially horizontal direction inside the frame part 112. In addition, the base portion 110 has an opening 116 formed by the upper edge of the shade connecting portion 114 and the inner peripheral edge of the frame portion 112 above the shade connecting portion 114. The opening 116 allows light source light to enter the projection lens 34.

  A plurality of through holes 118 extending in the front-rear direction of the lamp are provided at predetermined positions of the frame portion 112. A first shade 130 and a second shade 140 are connected to the shade connecting portion 114. The first shade 130 and the second shade 140 are provided so as to be able to swing independently with respect to the shade connecting portion 114, and a position where a part of the periphery of the opening 116 is blocked and an outer periphery of the periphery of the opening 116. It can be displaced to a position extending to The optical unit 100 is disposed so that the upper edge of each shade overlaps the second focal point of the reflecting surface of the reflector unit 30 when each shade is displaced to a position where it covers a part of the periphery of the opening 116. The structure of the optical unit 100 will be described in detail later.

  The reflector 30 and the optical unit 100 have their mutual positional relationship determined by inserting each positioning projection 30b through a predetermined through-hole 118. Further, the lens holder 32 has a positional relationship with respect to the reflector unit 30 and the optical unit 100 determined by inserting a predetermined positioning convex portion 30b protruding from the through hole 118 of the optical unit 100 into the predetermined through hole 32c. Yes. In this state, the predetermined through hole 30c of the reflector portion 30, the predetermined through hole 118 of the optical unit 100, and the predetermined through hole 32c of the lens holder 32 overlap with each other when viewed from the front of the lamp, and are fastened with screws or the like. The member 36 is inserted and the reflector part 30, the optical unit 100, and the lens holder 32 are connected.

  Next, the structure of the optical unit 100 according to the embodiment will be described in detail. FIG. 4 is an exploded perspective view of the optical unit according to the embodiment. As shown in FIG. 4, the optical unit 100 according to the present embodiment is an optical unit used for a vehicular lamp, and includes a base 110, a first shade 130, a second shade 140, a first motor 150A, a second A motor 150B, a first case 170A, and a second case 170B are included. Hereinafter, when the first motor 150A and the second motor 150B are not particularly distinguished, they are collectively referred to as the motor 150. In addition, when the first case 170A and the second case 170B are not particularly distinguished, they are collectively referred to as the case 170.

  The base part 110 has the frame part 112, the shade connection part 114, the opening part 116, and the through-hole 118 as mentioned above. Furthermore, the base portion 110 has a first shade support shaft 120A that protrudes forward of the lamp at the right end (in the vehicle width direction) end of the shade connecting portion 114 when viewed from the front of the lamp. A second shade support shaft 120 </ b> B that protrudes forward of the lamp is provided at the left end (outer side in the vehicle width direction). The base portion 110 has a plurality of case fixing through holes 121A, a plurality of fitting portions 122A, and an output shaft through hole 123A in a region on the right side of the frame portion 112 when viewed from the front of the lamp. The left region of 112 has a plurality of case fixing through holes 121B, a plurality of fitting portions 122B, and an output shaft through hole 123B. In the present embodiment, the fitting portions 122A and 122B are through holes.

  In addition, the base portion 110 has a first shade first stopper 124A and a second shade first stopper 124B in a region on the inner peripheral edge side of the frame portion 112, and in a region on the outer peripheral edge side of the frame portion 112. The first shade second stopper 125A and the second shade second stopper 125B are provided. When viewed from the front of the lamp, the first shade first stopper 124A and the first shade second stopper 125A are disposed in the right region of the base 110, and the second shade first stopper 124B and the second shade second stopper. 125B is arranged in the left region of the base 110. Each stopper protrudes forward of the lamp. Further, the base portion 110 has a return spring locking hole 126 and a return spring locking hole 127 (see FIGS. 9A to 9C and FIG. 10B) at predetermined positions of the frame portion 112. .

  Each of the first shade 130 and the second shade 140 has a substantially L shape, extends in a substantially horizontal direction, and includes horizontal portions 132 and 142 used for blocking light source light, and horizontal portions 132 and 142. It has vertical portions 134 and 144 that extend substantially vertically downward from one end and receive the rotational force of the motor 150. The edge 132a of the horizontal portion 132 of the first shade 130 is processed so as to form a cut-off line of the low beam light distribution pattern when the first shade 130 is in an advanced position described later. The edge 142a of the horizontal portion 142 of the second shade 140 is processed so as to form a cut-off line of the one-high light distribution pattern when the second shade 140 is in the advanced position described later. At the lower ends of the vertical portions 134 and 144, gear portions 135 and 145 that mesh with connection portions (described later) provided on the output shaft of the motor 150 are provided.

  The 1st shade 130 and the 2nd shade 140 have the cylinder parts 136 and 146 which protrude ahead of a lamp | ramp in the junction part vicinity of the horizontal parts 132 and 142 and the vertical parts 134 and 144, respectively. Further, the first shade 130 and the second shade 140 have return spring locking grooves 138 and 148 at predetermined positions, respectively. The first shade 130 is held by the base portion 110 with the first shade support shaft 120 </ b> A inserted through the cylindrical portion 136. Accordingly, the first shade 130 is disposed on the inner side in the vehicle width direction. The horizontal portion 132 extends toward the second shade support shaft 120B. The vertical portion 134 extends between the first shade first stopper 124A and the first shade second stopper 125A, and the gear portion 135 is disposed in the vicinity of the output shaft through hole 123A.

  The second shade 140 is held by the base portion 110 with the second shade support shaft 120 </ b> B inserted through the cylindrical portion 146. Accordingly, the second shade 140 is disposed on the outer side in the vehicle width direction. The horizontal portion 142 extends toward the first shade support shaft 120A. The vertical portion 144 extends between the second shade first stopper 124B and the second shade second stopper 125B, and the gear portion 145 is disposed in the vicinity of the output shaft through hole 123B.

  Retaining rings 102 and return springs 104A and 104B are fitted in this order on the outer circumferences of the cylindrical portions 136 and 146, respectively. The return springs 104A and 104B are constituted by, for example, torsion coil springs, and have coil portions whose both ends extend in an arm shape. With the first shade 130 held by the base portion 110, one end of the return spring 104 </ b> A is inserted into the return spring locking hole 126 and the other end is locked by the return spring locking groove 138. In the state where the second shade 140 is held by the base portion 110, one end of the return spring 104 </ b> B is inserted into the return spring locking hole 127 and the other end is locked by the return spring locking groove 148.

  The motor 150 is accommodated in the case 170 and fixed to the base portion 110 via the case 170. FIG. 5 is a perspective view showing a schematic structure of the motor and the case. FIG. 6 is a schematic sectional view of the motor and the case. FIGS. 7A and 7B are perspective views for explaining the connection between the motor and the power supply terminal. FIG. 6 shows a state in which the motor 150 is housed in the case 170 and shows a cross section along the output shaft 152 of the motor 150.

  As shown in FIGS. 5 to 7B, the motor 150 is formed of, for example, a DC motor, and includes a housing 151, an output shaft 152, and terminal connection portions 153A and 153B. The housing 151 includes a top surface 151a from which the output shaft 152 protrudes, a bottom surface 151b facing the top surface 151a, substantially flat first side surfaces 151c and second side surfaces 151d facing each other, curved third side surfaces 151e facing each other, and And a fourth side surface 151f. The upper surface 151a and the bottom surface 151b are provided with boss portions 154a and 154b that protrude slightly outward and house the bearings therein.

  The output shaft 152 is provided with a connecting portion 160 formed of a gear such as a spur gear. The output shaft 152 is connected to the first shade 130 or the second shade 140 via the connection unit 160. The power supply terminal connection portions 153A and 153B are provided in the vicinity of the bottom surface 151b of the first side surface 151c of the housing 151. The terminal connection portion 153A corresponds to one of the anode and the cathode, and the terminal connection portion 153B corresponds to the other of the anode and the cathode.

  The case 170 includes a wall portion 172, an accommodation space 174, an opening portion 176, a connector 178, power supply terminals 180A and 180B, and wiring portions 182A and 182B. The wall portion 172 includes a substantially rectangular bottom wall portion 172a, a first wall portion 172b, a second wall portion 172c, a third wall portion 172d, and a fourth wall portion 172e. The first wall portion 172b and the fourth wall portion 172e face each other. The second wall portion 172c and the third wall portion 172d face each other and extend substantially perpendicular to the first wall portion 172b and the fourth wall portion 172e. The first wall portion 172b, the second wall portion 172c, the third wall portion 172d, and the fourth wall portion 172e constitute side walls, and the four side walls and the bottom wall 172a accommodate the motor 150. A space 174 is formed. The lower ends of the four side wall portions are connected to the peripheral edge portion of the bottom wall portion 172a, but the wall portion 172 is not provided on the upper end side. That is, an opening 176 for inserting the motor 150 into the accommodation space 174 is provided on the upper end side of the four side wall portions.

  The connector 178 has an insertion port 178m into which an external power supply terminal is inserted, and connector terminals 178A and 178B arranged in the insertion port 178m, and is provided on the outer surface of the fourth wall portion 172e. The power supply terminals 180 </ b> A and 180 </ b> B are exposed in the accommodation space 174. One end of the wiring portion 182A is connected to the connector terminal 178A, is routed from the connector 178 to the accommodation space 174, and the other end is connected to the power supply terminal 180A. One end of the wiring portion 182B is connected to the connector terminal 178B, is routed from the connector 178 to the accommodation space 174, and the other end is connected to the power supply terminal 180B. As a result, the power supply terminals 180A and 180B are electrically connected to the connector 178. The terminal of the external power supply is inserted into the insertion port 178a and connected to the connector terminals 178A and 178B in the insertion port 178a. Thereby, the connector 178 is connected to the external power supply (see FIG. 1). The electric power sent from the external power source is supplied to the motor 150 via the connector terminals 178A and 178B, the wiring portions 182A and 182B, and the power supply terminals 180A and 180B.

  The motor 150 is disposed such that the first side surface 151c faces the bottom wall portion 172a. Therefore, the opening 176 is disposed substantially parallel to the axial direction of the output shaft 152. The motor 150 is pressed in a direction substantially perpendicular to the axial direction of the output shaft 152 and closer to the distance between the first side surface 151c and the bottom wall portion 172a, and is accommodated through the opening 176. It is inserted into the space 174. With the motor 150 housed in the case 170, the top surface 151a and the first wall portion 172b, the bottom surface 151b and the fourth wall portion 172e, the first side surface 151c and the bottom wall portion 172a, the third side surface 151e and the second wall portion 172c. The fourth side surface 151f and the third wall portion 172d face each other.

  Here, the power supply terminals 180A and 180B are arranged in the storage space 174 so that the terminal connection portions 153A and 153B and the power supply terminals 180A and 180B are in physical contact when the motor 150 is inserted into the storage space 174. Yes. In the present embodiment, terminal connection portions 153A and 153B are provided in the vicinity of the bottom surface 151b on the first side surface 151c. For this reason, the power supply terminals 180A and 180B project from the vicinity of the fourth wall portion 172e in the bottom wall portion 172a facing the first side surface 151c in a state where the motor 150 is accommodated in the accommodation space 174. Therefore, when the motor 150 is inserted into the case 170, the power supply terminals 180A and 180B are inserted into the terminal connection portions 153A and 153B at the same time that the motor 150 is accommodated in the case 170. Therefore, according to the optical unit 100 of the present embodiment, the housing of the motor 150 in the case 170 and the electrical connection between the motor 150 and the connector 178 can be performed simultaneously. Simplification can be achieved.

  The fourth wall 172e of the case 170 is provided with a slit 172e1 into which the boss 154b of the motor 150 is inserted. In addition, a fixing hook portion 184 that protrudes toward the slit 172e1 is provided between the fourth wall portion 172e and the connector 178. When the motor 150 is inserted into the case 170, the fixing hook portion 184 is elastically deformed by being pressed by the boss portion 154b of the motor 150, and is displaced toward the outside of the slit 172e1. When the motor 150 is completely accommodated in the case 170, the fixing hook portion 184 gets over the boss portion 154b, the pressing of the fixing hook portion 184 by the boss portion 154b is released, and the fixing hook portion 184 is The state before displacement is restored by elasticity. As a result, the boss portion 154b of the motor 150 and the fixing hook portion 184 engage with each other, and the bottom surface 151b side portion of the motor 150 is prevented from coming out of the housing space 174.

  In addition, the first wall portion 172b in contact with the opening 176 is divided into a first portion 172b2 and a second portion 172b3 by a slit 172b1 extending from the opening 176. Further, a boss receiving portion 172b4 protruding from the bottom wall portion 172a side is provided in the slit 172b1. The boss receiving part 172b4 constitutes a part of the first wall part 172b. The first portion 172b2 and the second portion 172b3 have protrusions 172b5 and 172b6 that protrude toward the slit 172b1 on the surfaces in contact with the slit 172b1, respectively. Due to the protruding portions 172b5 and 172b6, a constricted portion having a slit width smaller than that of the other region is formed in the slit 172b1. The slit width in the constricted portion is set smaller than the diameter of the boss portion 154a.

  When the motor 150 is inserted into the case 170, the first wall portion 172 b is deformed by the boss portion 154 a of the motor 150 and the motor 150 is allowed to enter the case 170. In a state where the motor 150 is accommodated in the case 170, the output shaft 152 projects outside from the accommodation space 174 via the slit 172b1.

  FIG. 8A to FIG. 8C are views for explaining the shape change of the first wall portion when the motor is accommodated in the case. First, as shown in FIG. 8A, when the motor 150 is inserted into the case 170, the boss portion 154a enters the slit from the open end of the slit 172b1. And the boss | hub part 154a is pushed forward toward the constriction part of the slit 172b1 formed of the protrusion part 172b5 and the protrusion part 172b6 (refer FIG. 5).

  As shown in FIG. 8B, when the boss portion 154a approaches the constricted portion, the projecting portions 172b5 and 172b6 are pressed by the boss portion 154a in the direction in which the slit width of the constricted portion increases. Accordingly, the first wall portion 172b is elastically deformed, and the first portion 172b2 and the second portion 172b3 are displaced in a direction away from each other (a direction indicated by an arrow in FIG. 8B). As a result, the motor 150 is allowed to enter the accommodation space 174 (see FIG. 5).

  As shown in FIG. 8C, when the boss portion 154a is further pushed through the slit 172b1, the boss portion 154a passes through the constricted portion and gets over the protruding portions 172b5 and 172b6. Then, the lower end of the boss portion 154a hits the boss receiving portion 172b4, and the motor 150 is accommodated in the accommodation space 174. In this state, the pressing of the protruding portions 172b5 and 172b6 by the boss portion 154a is released, and the first portion 172b2 and the second portion 172b3 are displaced from each other by the elasticity (the position shown in FIG. 8B) (see FIG. 8B). 8 (C) is displaced in the direction indicated by the arrow). Thereby, the displacement of the boss 154a in the direction toward the open end of the slit 172b1 is restricted by the protrusions 172b5 and 172b6. As a result, the separation of the motor 150 from the accommodation space 174 is suppressed.

  Thus, the optical unit 100 according to the present embodiment fixes the motor 150 to the case 170 by so-called snap fit. Therefore, the manufacturing process of the optical unit 100 can be simplified. Further, since a cover that closes the opening 176 is not required to prevent the motor 150 from falling off the case 170, it is possible to realize a reduction in cost and weight by reducing the number of parts of the optical unit 100.

  As shown in FIGS. 4, 5 and 8, the first portion 172b2 of the first wall portion 172b includes a first flange portion 186 protruding in the surface direction of the first wall portion 172b, and the second portion 172b3 is A second flange portion 187 protruding in the surface direction of the first wall portion 172b is included. The first flange portion 186 and the second flange portion 187 are each provided with a fixing mechanism 188 for fixing the case 170 to the base portion 110. In the present embodiment, the fixing mechanism 188 is an insertion hole through which a fastening member such as a screw is inserted. Each of the first portion 172b2 and the second portion 172b3 has a positioning convex portion 189. The positioning convex portion 189 is provided on a surface in contact with the base portion 110 in a state where the case 170 is fixed to the base portion 110, and protrudes substantially parallel to the axial direction of the output shaft 152.

  As shown in FIG. 4, the case 170 is attached to the base portion 110 such that the first wall portion 172 b is in contact with the main surface of the frame portion 112 of the base portion 110 on the rear side of the lamp. Therefore, the motor 150 is disposed such that the output shaft 152 is substantially perpendicular to the surface of the base portion 110 with which the case 170 abuts.

  The first case 170 </ b> A is attached to the base portion 110 such that the fixing mechanism 188 that is a through hole is aligned with the case fixing through-hole 121 </ b> A of the base portion 110. When the first case 170A is attached to the base portion 110, the output shaft 152 and the connection portion 160 of the first motor 150A are inserted into the output shaft through hole 123A of the base portion 110, and the teeth of the connection portion 160 that is a gear are the first. It meshes with the gear portion 135 of one shade 130 (see FIG. 3). Further, the positioning convex portion 189 is fitted into the fitting portion 122A of the base portion 110, whereby the first case 170A is positioned with high accuracy with respect to the base portion 110. The first case 170A is fixed to the base portion 110 by inserting a fastening member 200 such as a screw through the fixing mechanism 188 of the first case 170A and the case fixing through hole 121A of the base portion 110.

  The second case 170 </ b> B is attached to the base portion 110 with the fixing mechanism 188 being a through hole aligned with the case fixing through-hole 121 </ b> B of the base portion 110. When the second case 170B is attached to the base portion 110, the output shaft 152 and the connection portion 160 of the second motor 150B are inserted into the output shaft through-hole 123B of the base portion 110, and the teeth of the connection portion 160 that is a gear are the first. It meshes with the gear portion 145 of the two shades 140 (see FIG. 3). Further, the positioning convex portion 189 is fitted into the fitting portion 122B of the base portion 110, whereby the second case 170B is positioned with high accuracy with respect to the base portion 110. The second case 170B is fixed to the base portion 110 by inserting a fastening member 200 such as a screw through the fixing mechanism 188 of the second case 170B and the case fixing through hole 121B of the base portion 110.

  In the present embodiment, the case 170 has a fixing mechanism 188 in the first flange portion 186 and the second portion 172b3 and the second flange portion 187 of the first portion 172b2, and the first portion 172b2 and the second portion 172b3 are the bases, respectively. It is fixed with respect to the part 110. Therefore, the displacement of the first portion 172b2 and the second portion 172b3 in the direction away from each other is suppressed while the case 170 is fixed to the base portion 110. Therefore, it is possible to prevent the motor 150 from dropping from the case 170 using a mechanism for attaching the case 170 to the base portion 110. Further, since the positioning convex portion 189 is also provided in the first portion 172b2 and the second portion 172b3, the positioning convex portion 189 can also suppress the displacement of the first portion 172b2 and the second portion 172b3 in the direction away from each other. it can. Therefore, it is possible to prevent the motor 150 from dropping from the case 170 using a positioning mechanism for the case 170 to the base portion 110.

  The case fixing through-holes 121A and 121B and the fixing mechanism 188 are improved in dimensional accuracy, and the case fixing through-holes 121A and 121B, the fixing mechanism 188 and the fastening member 200 are used to increase the accuracy of the case 170 relative to the base 110. Positioning may be performed. In this case, the positioning projection 189 can be omitted. In the present embodiment, the case fixing through-hole 121A and the fixing mechanism 188 are used as through-holes, and the case 170 is fixed to the base portion 110 using the fastening member 200. It may be adopted.

  Next, the displacement of the first shade 130 and the second shade 140 and the light distribution pattern that can be formed by the optical unit 100 will be described. FIG. 9A to FIG. 9C are diagrams for explaining the states of the first shade and the second shade and the light distribution pattern to be formed. 9A to 9C show the optical unit 100 viewed from the front of the lamp.

  The first shade 130 and the second shade 140 have the first shade support shaft 120A and the second shade support shaft 120B as rotation axes, respectively, and the advance position where a part of the light source light is shielded and the part of the light source light that is not used. It can be displaced to the retracted position for light shielding. Each shade is displaced from one of the advanced position and the retracted position by the rotation of the output shaft 152 of the motor 150. Further, when the motor 150 is turned off, each shade is displaced from the other to the one by the urging force of the return springs 104A and 104B.

  In the present embodiment, the force from the output shaft 152 of the first motor 150 </ b> A is transmitted to the first shade 130 via the connection portion 160, and is displaced from the advanced position to the retracted position by the rotation of the output shaft 152. The first shade 130 that is displaced toward the retracted position abuts against the first shade second stopper 125A and stops at the retracted position. Further, the first shade 130 is displaced from the retracted position to the advanced position by the urging force of the return spring 104A when the first motor 150A is turned off. The first shade 130 that is displaced toward the advanced position abuts against the first shade first stopper 124A and stops at the advanced position. In this manner, the first shade 130 for forming the low beam light distribution pattern is configured to return to the advanced position by the return spring 104A, so that the optical unit 100 can generate the high beam light distribution pattern or the single high light distribution pattern. A fail-safe function can be realized by reliably avoiding being fixed in the forming posture.

  On the other hand, in the second shade 140, the rotation of the output shaft 152 of the second motor 150B is transmitted through the connecting portion 160, and the second shade 140 is displaced from the retracted position to the advanced position by the rotation of the output shaft 152. The second shade 140, which is displaced toward the advanced position, abuts against the second shade first stopper 124B and stops at the advanced position. Further, when the second motor 150B is turned off, the second shade 140 is displaced from the advanced position to the retracted position by the urging force of the return spring 104B. The second shade 140, which is displaced toward the retracted position, abuts against the second shade second stopper 125B and stops at the retracted position.

  As shown in FIG. 9A, the lamp unit 10 can form a low beam light distribution pattern with the first shade 130 in the advanced position and the second shade 140 in the retracted position. As shown in FIG. 9B, the lamp unit 10 can form a high-beam light distribution pattern in a state where the first shade 130 and the second shade 140 are in the retracted position. Further, as shown in FIG. 9C, the lamp unit 10 has a high beam region only on the opposite lane side when passing on the left side with the first shade 130 in the retracted position and the second shade 140 in the advanced position. A so-called right-side high light distribution pattern can be formed. In the lamp unit of the headlamp unit disposed on the left side of the vehicle, the first shade 130 is disposed on the left side (in the vehicle width direction) and the second shade 140 is disposed on the right side (the vehicle width direction outer side) when viewed from the front of the lamp. Placed in. Then, the lamp unit can form a low beam light distribution pattern, a high beam light distribution pattern, and a so-called left-side high light distribution pattern having a high beam region only on the own lane when passing on the left side. Since the shape of each light distribution pattern mentioned above is well-known, detailed description is abbreviate | omitted.

  Here, the mounting posture of the case 170 to the base portion 110 will be described. FIG. 10A is an enlarged view of the vicinity of the gear portion of the first shade. FIG. 10B is an enlarged view of the vicinity of the gear portion of the second shade. FIG. 11 is a diagram illustrating a schematic structure of the optical unit viewed from the rear of the lamp. As shown in FIG. 10A, when the output shaft 152 of the first motor 150A rotates in the direction of arrow S, the first shade 130 moves from the advanced position to the retracted position against the urging force of the return spring 104A. Displace. Then, it comes into contact with the first shade second stopper 125A and stops at the retracted position. Even after the first shade 130 stops at the retracted position, the rotational force of the output shaft 152 of the first motor 150A is transmitted to the first shade 130, and the first shade 130 continues to be pressed by the connecting portion 160. 130 is maintained in the retracted position.

  While the first shade 130 is maintained at the retracted position, the contact F between the connecting portion 160 and the gear portion 135 is continuously applied with the force F1 in the direction of pressing the first shade 130 against the first shade second stopper 125A. . On the other hand, the displacement of the first shade 130 is restricted by the first shade second stopper 125A. Therefore, the first motor 150A receives a reaction force of the force F1 and uses the contact T as a fulcrum, and the direction X1 (contact T and the output shaft 152) is substantially opposite to the direction in which the vertical portion 134 of the first shade 130 is urged. To move in a direction substantially perpendicular to the straight line connecting the two.

  Further, as shown in FIG. 10B, when the output shaft 152 of the second motor 150B rotates in the direction of the arrow S, the second shade 140 moves from the retracted position to the advanced position against the urging force of the return spring 104B. Displace towards. And it contacts the 1st stopper 124B for 2nd shades, and stops in an advance position. Even after the second shade 140 stops at the advanced position, the rotational force of the output shaft 152 of the second motor 150B is transmitted to the second shade 140, and the second shade 140 continues to be pressed by the connecting portion 160. 140 is maintained in the advanced position.

  While the second shade 140 is maintained at the advanced position, the contact F between the connecting portion 160 and the gear portion 145 is continuously applied with the force F1 in the direction in which the second shade 140 is pressed against the second shade first stopper 124B. . On the other hand, the displacement of the second shade 140 is restricted by the second shade first stopper 124B. Therefore, the second motor 150B receives a reaction force of the force F1, and uses the contact T as a fulcrum, the direction X2 (contact T and output shaft 152 and the direction substantially opposite to the direction in which the vertical portion 144 of the second shade 140 is urged). To move in a direction substantially perpendicular to the straight line connecting the two.

  Therefore, as shown in FIG. 11, the case 170 is moved to the front end side in the directions X <b> 1 and X <b> 2 in which the motor 150 is displaced by the force applied to the motor 150 by the connection portion 160 continuously pressing the shade that is in contact with the stopper. The posture with respect to the base portion 110 is determined and fixed to the base portion 110 so that at least a part of the wall portion 172 extends. In the present embodiment, when the first shade 130 that is in contact with the first shade second stopper 125A is continuously pressed, the first motor 150A tends to be displaced in the lower right direction X1 when viewed from the rear of the lamp. . On the other hand, the bottom wall portion 172a of the first case 170A extends on the distal end side in the direction X1 in which the first motor 150A is displaced.

  Further, as the second shade 140 abutting against the second shade first stopper 124B is continuously pressed, the second motor 150B tends to be displaced in the direction X2 substantially at the upper right when viewed from the rear of the lamp. On the other hand, the bottom wall portion 172a of the second case 170B extends on the distal end side in the direction X2 in which the second motor 150B is displaced.

  Thereby, since the displacement of the motor 150 can be regulated by the wall portion 172 of the case 170, the motor 150 can be more reliably suppressed from falling off the case 170. Therefore, according to the optical unit 100 of the present embodiment, it is possible to maintain the determined mounting posture of the motor, so that the operational reliability of the optical unit 100 can be improved.

  Subsequently, the arrangement of the advance position and the retreat position of the first shade 130 and the second shade 140 will be described. FIG. 12A is an exploded perspective view showing a schematic structure of the motor. FIG. 12B is a schematic diagram of the internal structure of the motor.

  As shown in FIGS. 12A and 12B, the motor 150 includes a commutator 155 (see FIG. 7A) in addition to the housing 151, the output shaft 152, and the terminal connection portions 153A and 153B described above. Commutator), a pair of brushes 156, a brush arm 157, a core 158, a winding 159, and a plurality of magnets 162. The commutator 155 has a cylindrical shape and is press-fitted into the output shaft 152. Therefore, the commutator 155 rotates with the output shaft 152. The commutator 155 has a plurality of commutator pieces 155 a arranged at intervals around the output shaft 152. In the present embodiment, there are three commutator pieces 155a.

  The pair of brushes 156 are arranged with the commutator 155 interposed therebetween. The two brushes 156 are respectively attached to the tips of the brush arms 157 and are held so that the tip surfaces are in sliding contact with the outer peripheral surface of the commutator 155. One of the two brush arms 157 is connected to the terminal connection portion 153A, and the other is connected to the terminal connection portion 153B. The core 158 is press-fitted into the output shaft 152 in a state where the winding 159 is wound. The plurality of magnets 162 are provided along the inner surface of the housing 151 and are arranged at intervals in the circumferential direction. The core 158 is disposed so that its outer peripheral surface is opposed to the inner peripheral surface of the magnet 162 with a predetermined clearance (magnetic gap). Since the structure of the motor 150 is known, further detailed description is omitted.

Here, the advance position and the retreat position of the first shade 130 and the second shade 140 are set so that the angle θ at which the output shaft 152 rotates when the shade is displaced by the motor 150 satisfies the following expression (1). Yes.
Formula (1): θ ≧ 360 ° / n (n is the number of commutator pieces)

  Further, in the present embodiment, the positional relationship between the first shade first stopper 124A and the first shade second stopper 125A, and the second shade first stopper 124B and the second shade second stopper 125B. The positional relationship is determined so that each angle θ satisfies the above formula (1).

  In the motor 150, when the rotation of the output shaft 152 is repeated, the tip of the brush 156 is worn and metal powder is generated. When the metal powder enters the gap 155b between the adjacent commutator pieces 155a, the motor 150 may short-circuit between the commutator pieces 155a. On the other hand, the advancing position and the retracted position are set so that the rotational angle θ of the output shaft 152 when the shade is displaced satisfies the above formula (1). When the rotation angle θ of the output shaft 152 satisfies the above formula (1), the angle θ at which the output shaft 152 rotates when the shade is displaced is equal to or greater than the angular interval at which the gap 155b is disposed. Therefore, the brush 156 can be passed over the gap 155b between the commutator pieces 155a more reliably.

  In the present embodiment, the motor 150 has three commutator pieces 155 a, and the three commutator pieces 155 a are arranged at equal intervals around the output shaft 152. Therefore, the gap 155b is arranged at an interval of approximately 120 °. The advance position and the retreat position are set so that the angle θ at which the output shaft 152 rotates while the shade is displaced is 120 ° or more. Therefore, when the shade is displaced, the brush 156 almost certainly straddles the gap 155b.

  When the brush 156 straddles the gap 155b between the commutator pieces 155a, a spark is generated between the brush 156 and the commutator 155. The metal powder is oxidized by this spark and loses conductivity. Therefore, by designing the rotation angle θ of the output shaft 152 when the shade is displaced so as to satisfy the above formula (1), sparks can be generated more reliably, and a short circuit between the commutator pieces 155a due to metal powder can be prevented. This can be avoided more reliably. As a result, the motor 150 can be operated normally for a longer period of time, and the operation reliability of the optical unit 100 can be improved.

  As described above, the optical unit 100 according to the present embodiment rotates the output shaft 152 when the first shade 130 and the second shade 140 are displaced from the advanced position to the retracted position or from the retracted position to the advanced position. The advance position and the retracted position of the first shade 130 and the second shade 140 are set so that the angle θ satisfies the above formula (1). Thereby, since the motor 150 can be operated normally for a longer period of time, the operation reliability of the optical unit can be improved.

  Further, in the optical unit 100 according to the present embodiment, the wall portion 172 is disposed on the distal end side in the direction in which the motor 150 is displaced by the force applied to the motor 150 as the connecting portion 160 continues to press the shade in contact with the stopper. The mounting posture of the case 170 with respect to the base portion 110 is determined so that at least a part thereof extends. As a result, it is possible to more reliably suppress the motor 150 from dropping from the case 170, and thus the operational reliability of the optical unit 100 can be improved.

  Further, in the optical unit 100 of the present embodiment, when the motor 150 is inserted into the accommodation space 174, the power supply terminal 180A is so arranged that the terminal connection portions 153A, 153B and the power supply terminals 180A, 180B are in physical contact. , 180B are disposed in the accommodation space 174. Thereby, since the housing of the motor 150 in the case 170 and the electrical connection between the motor 150 and the connector 178 can be performed at the same time, the manufacturing process of the optical unit 100 can be simplified.

  The present invention is not limited to the above-described embodiments, and various modifications such as design changes can be added based on the knowledge of those skilled in the art. Embodiments to which such modifications are added Are also included within the scope of the present invention. A new embodiment in which a modification is added to the above-described embodiment has the effects of the combined embodiment and the modification.

  DESCRIPTION OF SYMBOLS 1 Vehicle lamp, 100 Optical unit, 150 Motor, 152 Output shaft, 155 Commutator, 155a Commutator piece, 156 Brush, 160 Connection part, 170 case, 170A 1st case, 170B 2nd case, 172 Wall part, 172b1 Slit, 172b2 first part, 172b3 second part, 174 accommodation space, 176 opening, 178 connector, 180A, 180B feeding terminal, 186 first flange part, 187 second flange part, 188 fixing mechanism, 189 positioning convex part.

Claims (4)

An optical unit used in a vehicle lamp,
A shade that is displaceable between an advancing position where a part of the light source light is shielded and a retreat position where the part of the light source light is not shielded;
A motor having a terminal connection for power feeding and an output shaft connected to the shade, and displacing the shade from one of the advanced position and the retracted position by rotation of the output shaft;
A wall forming a housing space for the motor, an opening for inserting the motor into the housing space, a connector connected to an external power source, and a power supply terminal electrically connected to the connector and exposed in the housing space A case having
The optical unit, wherein the power supply terminal is arranged in the housing space so that the terminal connection portion and the power feeding terminal are in physical contact when the motor is inserted into the housing space. The first wall part in contact with the opening part among the wall parts is divided into a first part and a second part by a slit extending from the opening part,
The case is displaced in a direction in which the first portion and the second portion are separated from each other to allow the motor to enter the housing space, and when the motor is housed in the housing space, the first portion is moved. 2. The optical unit according to claim 1, wherein the portion and the second portion are displaced in a direction approaching each other from the displaced position to suppress separation of the motor from the accommodation space. A base portion for holding the shade;
The first wall portion abuts on the base portion,
The first portion includes a first flange portion protruding in a surface direction of the first wall portion,
The second portion includes a second flange portion protruding in a surface direction of the first wall portion,
The optical unit according to claim 2, wherein each of the first flange portion and the second flange portion is provided with a fixing mechanism for fixing the case to the base portion. A base portion for holding the shade;
The first wall portion abuts on the base portion,
Each of the first part and the second part has a positioning convex part on a surface in contact with the base part,
The optical unit according to claim 2, wherein the base portion has a fitting portion into which the positioning convex portion is fitted.

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