JP2016009577A - Vehicle head light and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To precisely adjust a position of a bright part formed on a screen by a beam of a vehicle head light being radiated on the screen.SOLUTION: A vehicle head light 1 includes: a light emitting element 110; a reflector 301 to which the light emitting element 110 is assembled and which reflects light emitted by the light emitting element 110; a rotary shaft 38 which is integrally molded with the reflector 301 and extends in a vertical direction; and a bracket 80 to which the reflector 301 is assembled, the bracket 80 including a bearing hole 838. The rotary shaft 38 is pivotally supported by the bearing hole 838, and the reflector 301 is fastened to the bracket 80.

Description

  The present invention relates to a vehicle headlamp and a method for manufacturing the same.

  Patent Document 1 discloses a vehicle headlamp capable of switching between a low beam and a high beam. The low beam lamp unit is a reflector type lamp, and the semiconductor light emitting element and the reflector are attached to the light source mounting portion, and the light source mounting portion is attached to the bracket. The high beam lamp unit is also a reflector type lamp, and a semiconductor light emitting element and a reflector are attached to the front portion of the bracket.

JP 2011-82117 A

By the way, the low beam has a cut-off, and when the low beam is applied to the front screen, a clear cut-off line appears on the upper edge of the bright part. In order not to dazzle the passengers of the oncoming vehicle, the position of the bright part and the cut-off line in the screen must be adjusted strictly.
Therefore, the problem to be solved by the present invention is to make it possible to precisely adjust the position of the bright part formed on the screen by irradiating the beam of the vehicle headlamp on the screen.

  In order to solve the above problems, the invention according to claim 1 is a light-emitting element, a reflector that is assembled with the light-emitting element, reflects light emitted by the light-emitting element, and is integrally formed with the reflector, An extending rotary shaft; and a bracket having the reflector assembled thereto and having a bearing portion, wherein the rotary shaft is pivotally supported by the bearing portion, and the reflector is fastened to the bracket. This is a vehicle headlamp.

  The invention according to claim 2 further includes: a base integrally formed with the reflector; and a boss integrally formed with the base so as to protrude from the base, wherein the rotating shaft extends from the base to the boss. The base is integrally formed so as to protrude in the same direction, the protruding end surface of the boss contacts the bracket, the boss supports the base and the bracket apart, and the bracket is fastened to the boss. The vehicle headlamp according to claim 1, wherein the vehicle headlamp is provided.

  The invention according to claim 3 further includes a guided portion integrally formed on the base so as to protrude from the base in the same direction as the boss, and the bracket has an arc shape centered on the bearing portion. The vehicle headlamp according to claim 2, further comprising a guide hole formed in the bracket, wherein the guided portion is inserted into the guide hole.

  The invention according to claim 4 has a claw formed in a convex shape on the guided portion so as to be integrated with the guided portion, and the claw is caught on the bracket around the guide hole. The vehicle headlamp according to claim 3.

  The invention according to claim 5 further includes a substrate on which the light emitting element is surface-mounted, the substrate abutting against the base on the opposite side of the boss, and the substrate being fastened to the base by thermal caulking. The vehicle headlamp according to any one of claims 2 to 4, characterized in that:

  The invention according to claim 6 is the vehicle headlamp according to claim 5, wherein the substrate is fastened to the base by screws.

  According to a seventh aspect of the present invention, there is provided a vehicle headlamp comprising: a light emitting element; a reflector to which the light emitting element is assembled and reflecting light emitted by the light emitting element; and a bracket to which the reflector is assembled. In the method, a rotating shaft that is integrally formed with the reflector and extends vertically is pivotally supported on a bearing portion formed on the bracket, and then the light emitting element is caused to emit light so that light from the light emitting element is emitted. The position of the bright portion in the screen is adjusted by tilting the reflector left and right around the rotation axis while projecting the bright portion of the reflected light onto the screen by reflecting the light on the reflector. Next, the vehicle headlamp manufacturing method is characterized in that the reflector is fastened to the bracket.

  According to the present invention, since the rotating shaft is pivotally supported by the bearing portion, in a state where the reflector is not fastened to the bracket, the position and orientation of the reflector are tilted by tilting the reflector left and right around the rotating shaft. Can be adjusted. By adjusting the position and orientation of the reflector, it is possible to adjust the position of the bright part formed by irradiating the front screen with the light reflected by the reflector. The position of the bright part is fixed by fastening the reflector to the bracket after the adjustment.

It is a perspective view of a vehicle headlamp. It is a disassembled perspective view of the vehicle headlamp. It is a longitudinal cross-sectional view of the vehicle headlamp. It is explanatory drawing of the light distribution of the vehicle headlamp.

  EMBODIMENT OF THE INVENTION Below, the form for implementing this invention is demonstrated using drawing. However, since the embodiments described below are provided with various technically preferable limitations for carrying out the present invention, the technical scope of the present invention is not limited to the following embodiments and illustrated examples. Absent.

  FIG. 1 is a perspective view of a vehicle headlamp 1 according to an embodiment of the present invention. FIG. 2 is an exploded perspective view of the vehicle headlamp 1.

  This vehicle headlamp 1 is housed inside the housing. The front surface of the housing is opened, the front opening of the housing is closed by a transparent outer lens, and the outer lens is fixed to the housing by adhesion or welding. The vehicle headlamp 1 and the housing are connected by an aiming mechanism (also referred to as an optical axis adjusting mechanism or an aiming mechanism). The aiming mechanism tilts the vehicle headlamp 1 vertically and horizontally.

The vehicle headlamp 1 is a variable light distribution traveling headlamp having two types of lighting modes.
When the vehicle headlamp 1 is lit in the first lighting mode, an adaptive traveling beam (hereinafter referred to as ADB (Adaptive Driving Beam)) is used by the vehicle headlamp 1 to drive the vehicle headlamp. 1 is irradiated forward. The light distribution of the ADB is automatically controlled so as to change depending on the situation ahead of the vehicle (the presence or absence of an oncoming vehicle, the distance to the oncoming vehicle, etc.). For example, a video signal captured by an in-vehicle camera is input to the control unit, and the control unit automatically controls light distribution of the ADB based on the video signal.
When the vehicular headlamp 1 is lit in the second lighting mode, a normal traveling beam is irradiated to the front of the vehicular headlamp 1 by the vehicular headlamp 1. The normal traveling beam is a high beam that does not have a cutoff and satisfies the light distribution standard of the traveling headlamp.

  The vehicle headlamp 1 is an assembly. Components of the vehicle headlamp 1 include light source units 11 to 16, fastening screws 21 to 29, reflector molded products 30, 40, and 50 for a beam with a cutoff, a reflector molded product 60 for a beam without a cutoff, and A bracket 80 or the like. A beam with a cut-off is a beam having a cut-off, and when the beam is irradiated on a virtual screen, a cut-off line (bright / dark boundary line) that divides a bright part and a dark part formed on the virtual screen appears. . A non-cut-off beam is a beam that does not have a cut-off, and when the beam is irradiated onto a virtual screen, the beam is clear between the bright part formed on the virtual screen and the surrounding dark part. Cut-off line does not appear.

  The light source unit 11 is fastened to the reflector molded product 30 by caulking, and the light source unit 11 is fastened to the reflector molded product 30 by a fastening screw 21. The same applies to the light source unit 12, the reflector molded product 40, and the fastening screw 22, and the same applies to the light source unit 13, the reflector molded product 50, and the fastening screw 23.

  Further, an assembly (subassembly) including the light source unit 11, the reflector molded product 30, and the fastening screw 21 is temporarily fixed to the bracket 80, and then finally tightened to the bracket 80 by the fastening screw 24. The same applies to the light source unit 12, the reflector molded product 40, and the fastening screw 25, and the same applies to the light source unit 13, the reflector molded product 50, and the fastening screw 26.

  The light source units 14 to 16 are fastened to the reflector molded product 60 by caulking, and the light source units 14 to 16 and the reflector molded product 60 are fastened to the bracket 80 by fastening screws 27 to 29.

The assembly of the light source unit 11, the reflector molded product 30, and the fastening screw 21 will be described in detail.
The light source unit 11 includes a semiconductor light emitting element 110 and a substrate 111.
The semiconductor light emitting device 110 is surface mounted on the substrate 111. Specifically, the semiconductor light emitting device 110 is surface-mounted on the front portion of the lower surface of the substrate 111.
Positioning caulking holes 112 to 115 are formed in the substrate 111, and these caulking holes 112 to 115 penetrate from the upper surface to the lower surface of the substrate 111. When viewed from above, these caulking holes 112 to 115 are arranged around the semiconductor light emitting device 110. Specifically, the semiconductor light emitting element 110 is disposed between the front and rear caulking holes 112 and 113, and is disposed between the left and right caulking holes 114 and 115.
A through hole 116 is formed in the substrate 111, and the through hole 116 penetrates from the upper surface to the lower surface of the substrate 111. When viewed from above, the through-hole 116 is disposed between the front and rear caulking holes 112 and 113. Further, the through-hole 116 has a longer width in the front-rear direction than a width in the left-right direction.
The light source units 12 to 16 are also provided in the same manner as the light source unit 11.

  The reflector molded product 30 is a resin molded product. The reflector molded product 30 includes a base 31, crimping protrusions 32 to 35, a boss 36, a boss 37, a rotating shaft 38, a guided portion 39, a temporary fixing claw 391, and a reflector 301. The base 31, the protrusions 32 to 35, the boss 36, the boss 37, the rotation shaft 38, the guided portion 39, the temporary fixing claw 391 and the reflector 301 are integrally formed. At least the front surface of the reflector 301 in the reflector molded product 30 is metallized, and the front surface of the reflector 301 is a mirror surface.

The base 31 is formed in a flat plate shape.
The reflector 301 is a curved reflector, and the front surface of the reflector 301 is formed in a concave shape, and the rear surface of the reflector 301 is formed in a convex shape. The upper end of the reflector 301 is connected to the lower surface of the base 31, and the reflector 301 hangs from the lower surface of the base 31. The reflector 301 is a parabolic reflector, and the front surface of the reflector 301 is formed in a free-form surface based on a rotating paraboloid. The rotationally symmetric axis of the paraboloid of revolution that is based on the front surface of the reflector 301 extends in the front-rear direction.

  An opening 311 is formed in the front portion of the base 31, and the opening 311 penetrates from the upper surface to the lower surface of the base 31. The opening 311 is positioned in front of the upper end of the reflector 301, and the rear edge of the opening 311 is formed along the upper end of the reflector 301.

  The crimping protrusions 32 to 35 protrude upward from the upper surface of the base 31. The caulking protrusions 32 to 35 are disposed around the opening 311, the opening 311 is disposed between the front and rear caulking protrusions 32 and 33, and the opening 311 is disposed between the left and right caulking protrusions 34 and 35. The crimping protrusions 32 to 35 are formed at positions corresponding to the crimping holes 112 to 115, respectively.

  The lower surface of the substrate 111 of the light source unit 11 is directed to the upper surface of the base 31, the substrate 111 is attached to the base 31 and placed, and the crimping protrusions 32 to 35 are inserted into the crimping holes 112 to 115, respectively. As shown in FIG. 3, the substrate 111 is fastened to the base 31 by flanges 320 and 330 formed by thermally crimping the tops of the caulking protrusions 32 and 33. The same applies to the right and left crimping protrusions 34 and 35 and the crimping holes 114 and 115. Here, FIG. 3 is a longitudinal sectional view passing through the caulking protrusion 32 and the caulking protrusion 33.

  The substrate 111 is positioned by inserting the crimping protrusions 32 to 35 into the crimping holes 112 to 115, respectively. The semiconductor light emitting device 110 is disposed at a geometric optical reference point on the mirror surface (front surface) of the reflector 301. The geometric optical reference point serves as a reference when designing the mirror surface of the reflector 301, and is at or near the focal point of the mirror surface of the reflector 301.

  In a state where the substrate 111 is fastened to the base 31 by heat caulking and the semiconductor light emitting element 110 is assembled to the reflector 301 via the substrate 111 and the base 31, the semiconductor light emitting element 110 is disposed inside the opening 311. The opening 311 is blocked by the substrate 111 from above.

  A boss 36 is formed on the lower surface of the base 31 so as to protrude downward from the lower surface of the base 31. The boss 36 is a boss with a female screw hole, and the screw hole of the boss 36 opens on the upper surface of the base 31. When projected from above, the boss 36 overlaps the through hole 116 of the substrate 111. The fastening screw 22 is inserted into the through hole 116, and the fastening screw 22 is screwed to the boss 36.

  The boss 37, the rotation shaft 38, and the guided portion 39 are formed on the lower surface of the base 31 so as to protrude downward from the lower surface of the base 31. The rotating shaft 38 is disposed in front of the boss 36, the boss 37 is disposed behind the boss 36, and the guided portion 39 is disposed behind the boss 36. When viewed from above, the rotary shaft 38, the boss 36, the boss 37, and the guided portion 39 are arranged in a straight line. Further, when viewed from above, the boss 37 overlaps the caulking protrusion 33.

The boss 37 is a boss with a female screw hole, and the screw hole of the boss 37 opens at the protruding end surface of the boss 37.
On the outer peripheral surface of the guided portion 39, a temporary fixing claw 391 is formed in a convex shape.

  The assembly of the light source unit 11, the reflector molded product 30, and the fastening screw 21 is configured as described above. The assembly of the light source unit 12, the reflector molded product 40 and the fastening screw 22 and the assembly of the light source unit 13, the reflector molded product 50 and the fastening screw 23 are the assembly of the light source unit 11, the reflector molded product 30 and the fastening screw 21. It is constructed in the same way as the product. However, the reflector 501 of the reflector molded product 50, the reflector 401 of the reflector molded product 40, and the reflector 501 of the reflector molded product 50 are all paraboloidal reflectors, but their mirror surfaces have different shapes or directions. .

  The assembly of the light source unit 11, the reflector molded product 30, and the fastening screw 21 is assembled to the bracket 80. The assembly will be described in detail.

The bracket 80 has a support plate 81 and tables 83 to 85.
The support plate 81 is formed in a rectangular frame shape. The support plate 81 is supported in a standing state by an aiming mechanism. Three different locations 811, 812, 813 of the support plate 81 are connected to the housing by a ball joint of an aiming mechanism, a first lead screw type linear motion mechanism, and a second lead screw type linear motion mechanism, respectively. The support plate 81 can be tilted up and down by rotating the lead screw (aiming screw) of the first lead screw type linear motion mechanism, and the support plate 81 can be moved left and right by rotating the second lead screw. Can be tilted.

  Tables 83 to 85 are provided in a plate shape. The rear ends of the tables 83 to 85 are connected to the lower portion of the support plate 81, and the tables 83 to 85 extend forward from the lower portion of the support plate 81. The tables 83 to 85 are arranged in a stepped manner, a standing wall 841 is provided between the table 83 and the table 84, and a standing wall 842 is provided between the table 84 and the table 85. The support plate 81, the tables 83 to 85, and the standing walls 841 and 842 are integrally formed.

  A bearing hole 838, a through hole 837, and a guide hole 839 are formed in the table 83 of the bracket 80. The bearing hole 838, the through hole 837, and the guide hole 839 penetrate the table 83 up and down.

  A bearing hole 838 is disposed in front of the through hole 837, and a guide hole 839 is disposed behind the through hole 837. When viewed from above, the bearing holes 838, the through holes 837, and the guide holes 839 are arranged in a straight line.

  The guide hole 839 is shorter in the front-rear direction than in the left-right direction. When viewed from above, the guide hole 839 is provided along an arc centered on the bearing hole 838.

  The bearing hole 838, the through hole 837, and the guide hole 839 are located at positions corresponding to the rotating shaft 38, the boss 37, and the guided portion 39 of the reflector molded product 30, respectively. The rotary shaft 38 is inserted into the bearing hole 838 from above the table 83 bearing hole, the guided portion 39 is inserted into the guide hole 839 from above the table 83, and the temporary fixing claw 391 is disposed on the lower surface of the table 83 around the guide hole 839. It is caught in. The radial load of the rotating shaft 38 is received by the inner surface of the bearing hole 838, and the rotating shaft 38 can rotate in the circumferential direction.

  As viewed from above, the boss 37 overlaps the through hole 837. Further, the projecting end surfaces of the boss 36 and the boss 37 are in contact with the table 83, the boss 36 and the boss 37 are raised with respect to the table 83, and the boss 36 and the boss 37 are located at a position where the base 31 is away from the table 83. Is supported by.

  The fastening screw 24 is passed through the through hole 837 from below the table 83, and the fastening screw 24 is screwed to the boss 37. The reflector molded product 30 is fixed to the bracket 80 by the fastening screw 24. After the vehicle headlamp 1 is completed, the fastening screw 24 is fastened, and the reflector 301 is fastened to the table 83 of the bracket 80 via the base 31 and the boss 37.

  In a state where the fastening screw 24 is not fastened before the vehicle headlamp 1 is completed, the reflector molded product 30 is temporarily fastened to the table 83 by the temporary fastening claws 391 being caught on the lower surface of the table 83. In the temporarily fixed state, the reflector molded product 30 can be tilted left and right around the rotation shaft 38 and the bearing hole 838. When the reflector molded product 30 is tilted, the guided portion 39 is guided by the guide hole 839 and moves along the circumferential direction around the rotation shaft 38.

  In the same manner as the assembly of the light source unit 11, the reflector molded product 30 and the fastening screw 21 is assembled to the table 83, the assembly of the light source unit 12, the reflector molded product 40 and the fastening screw 22 is assembled to the table 84. ing. Similarly, an assembly of the light source unit 13, the reflector molded product 50, and the fastening screw 23 is assembled to the table 85.

  The reflector molded product 60 is a resin molded product. The reflector molded product 60 includes reflectors 601 to 603, plate-like bases 631, 641, 651, and the like. The reflectors 601 to 603 and the bases 631, 641, 651 are integrally formed. Bases 631, 641, 651 are arranged in a stepped manner. Reflectors 601 to 603 are suspended from the lower surfaces of the bases 631, 641, and 651, respectively. The reflectors 601 to 603 are parabolic reflectors, and the concave surface in front of the reflectors 601 to 603 is formed in a free-form surface based on the rotating paraboloid.

  The caulking projections 632 to 635 and the opening 611 are formed on the base 631 in the same manner as the caulking projections 32 to 35 and the opening 311 are formed on the base 31 of the reflector molded product 30. The same applies to the bases 641 and 651.

Just as the light source unit 11 is fastened to the base 31 of the reflector molded product 30 by heat caulking, the light source unit 14 is fastened to the base 631 by heat caulking. That is, the caulking protrusions 632 to 635 are inserted into the caulking holes 142 to 145 formed in the substrate 141 of the light source unit 14, respectively, and the caulking protrusions 632 to 635 are thermally caulked to fasten the substrate 141 to the base 631. .
Similarly, the substrate 151 of the light source unit 15 is also fastened to the base 651 by heat caulking, and the substrate 161 of the light source unit 16 is also fastened to the base 651 by heat caulking.

  On the other hand, the bracket 80 has a three-stage stepped table 86. The table 86 extends forward from the support plate 81, and the table 86 and the support plate 81 are integrally formed. On each step of the table 86, bosses 863 to 865 with female screw holes are respectively provided in a convex shape. On the upper stage and the lower stage of the table 86, pedestals 873 and 875 are respectively provided in a convex shape.

  The base 631 is placed on the boss 863 and the base 873, the base 641 is placed on the boss 864, and the base 651 is placed on the boss 865 and the base 875.

The through hole 636 overlaps the screw hole on the protruding end surface of the boss 863. The fastening screw 27 is passed through the through hole 146 and the through hole 636, and the fastening screw 27 is screwed to the boss 865. Thus, the base 631 and the substrate 141 of the light source unit 14 are fastened together with the protruding end surface of the boss 865. In a state in which the substrate 141 of the light source unit 14 is permanently fastened to the boss 863 by the fastening screw 27, the semiconductor light emitting device 140 of the light source unit 14 has a geometric optical reference point (for example, the focal point of the mirror surface) of the mirror surface (front surface) of the reflector 601. Or in the vicinity thereof. The geometric optical reference point serves as a reference when designing the mirror surface of the reflector 301, and is at or near the focal point of the mirror surface of the reflector 301.
Similarly, the base 641 and the substrate 151 of the light source unit 15 are fastened to the protruding end surface of the boss 864 by the fastening screw 28, and the base 651 and the substrate 161 of the light source unit 16 are fastened to the protruding end surface of the boss 865 by the fastening screw 29. ing.

  As described above, the vehicle headlamp 1 has two types of lighting modes. In the first lighting mode, the semiconductor light emitting devices 110, 120, 130, 140, 150, and 160 of the light source units 11 to 16 selectively emit light according to the situation in front of the vehicle. That is, at least one of the semiconductor light emitting elements 110, 120, 130, 140, 150, and 160 is selected based on a video signal captured by the in-vehicle camera, the selected one emits light, and the one that is not selected is selected. Turns off. Switching of the semiconductor light emitting devices 110, 120, 130, 140, 150, and 160 changes the light distribution of the ADB irradiated by the vehicle headlamp 1.

The light emitted by the semiconductor light emitting device 110 is reflected forward by the reflector 301, and a beam having a cutoff (reflected light) is irradiated forward. When the virtual screen is opposed to the vehicle headlamp 1, the light reflected by the reflector 301 is irradiated on the virtual screen, thereby forming a bright portion B1 on the virtual screen (FIG. 4A). )reference). The virtual screen is a virtual projection plane that faces the vehicular headlamp 1 at a position away from the vehicular headlamp 1 and that extends horizontally from the vehicular headlamp 1 to the front (reference). Axis) is orthogonal to the virtual screen.
.

  FIG. 4A to FIG. 4F are explanatory diagrams of light distribution of the vehicle headlamp 1. The origin O shown in FIGS. 4A to 4F is the intersection of the optical axis of the vehicle headlamp 1 and the virtual screen, and the H line represents the horizontal plane passing through the optical axis of the vehicle headlamp 1 and the virtual plane. The crossing line of the screen, the V-line is the crossing line of the vertical plane passing through the optical axis of the vehicle headlamp 1 and the virtual screen, and the cross mark is the brightest hot spot in the bright part.

  As shown in FIG. 4A, the bright part B1 is formed on the own lane side with respect to the V line, and a cut-off line C1 is formed on the edge of the bright part B1 on the opposite lane side.

  The light emitted by the semiconductor light emitting device 120 is reflected forward by the reflector 401, and a beam having a cutoff is irradiated onto the virtual screen. Thereby, a bright portion B2 as shown in FIG. 4B is formed on the virtual screen. The bright part B2 is formed on the own lane side with respect to the V line, and a cut-off line C2 is formed on the edge of the bright part B2 on the opposite lane side.

  The light emitted by the semiconductor light emitting device 130 is reflected forward by the reflector 501 and a beam having a cutoff is irradiated onto the virtual screen. Thereby, a bright portion B3 as shown in FIG. 4C is formed on the virtual screen. The bright portion B3 is formed on the own lane side with respect to the V line, and a cut-off line C3 is formed on the opposite lane side edge of the bright portion B3.

  The cut-off lines C1 to C3 are parallel to the V line. Of the cutoff lines C1 to C3, the cutoff line C1 is farthest from the V line, and the cutoff line C3 is closest to the V line. Among the bright portions B1 to B3, the hot spot of the bright portion B1 is farthest from the origin O, and the hot spot of the bright portion B3 is closest to the origin O.

  The light emitted by the semiconductor light emitting element 140 is reflected forward by the reflector 601 and is distributed. As shown in FIG. 4 (d), the bright portion B4 extends in the vertical and horizontal directions with the origin O as the center. The bright portion B4 is line symmetric with respect to the V line.

  The light emitted by the semiconductor light emitting device 150 is reflected forward by the reflector 602 and distributed. As a result, a bright portion B5 as shown in FIG. 4E is formed on the virtual screen. The bright part B5 extends vertically and horizontally around the origin O, and the area of the opposite lane is wider than the area on the own lane side than the V line in the bright part B5.

  The light emitted by the semiconductor light emitting element 160 is reflected forward by the reflector 603 and distributed. As a result, a bright portion B6 as shown in FIG. 4F is formed on the virtual screen. The bright portion B6 extends vertically and horizontally around the origin O, and the area of the opposite lane is wider than the area on the own lane side than the V line in the bright portion B6.

  In any of the bright portions B4 to B6, the light intensity gradually decreases as the distance from the hot spot increases, the outer edges of the bright portions B4 to B6 become unclear, and a cut-off line (bright / dark boundary line) is formed on the outer edges of the bright portions B1 to B3. Not formed.

In the second lighting mode, all of the semiconductor light emitting elements 110, 120, 130, 140, 150, and 160 of the light source units 11 to 16 emit light. As a result, the luminous intensity distribution of the combined bright portions B1 to B6 formed on the virtual screen satisfies the light distribution standard of the traveling headlamp.
In the second lighting mode, the semiconductor light emitting elements 140, 150, 160 of the light source units 14-16 may emit light, and the semiconductor light emitting elements 110, 120, 130 of the light source units 11-13 may be turned off. As a result, the luminous intensity distribution of the light portions B4 to B6 formed on the virtual screen satisfies the light distribution standard of the traveling headlamp.

A method for manufacturing the vehicle headlamp 1 will be described.
First, the fastening screws 21 to 29 and the light source units 11 to 16 are prepared. Further, the reflector molded products 30 to 50, the reflector molded product 60, and the bracket 80 are molded by, for example, an injection molding method, so that the reflector molded products 30 to 50, the traveling beam reflector molded product 60 and the bracket 80 are formed. prepare.
The substrates 141, 151, 161 of the light source units 14-16 are fastened to the bases 631, 641, 651 of the reflector molded product 60 by thermal caulking, respectively.
Next, the base 631 is placed on the boss 863 and the base 873, the base 641 is placed on the boss 864, and the base 651 is placed on the boss 865 and the base 875. Then, the through hole 636 of the base 631 is aligned with the boss 863, and the bases 641 and 651 are aligned in the same manner. Next, the fastening screws 27 are fastened to the bosses 863, respectively. As a result, the substrate 141 and the base 631 are fastened together with the boss 863 by the fastening screw 27. The fastening screws 28 and 29 are similarly tightened.

  The caulking protrusions 32 to 35 of the reflector molded product 30 are inserted into the caulking holes 113 to 115, and the caulking protrusions 32 to 35 are heat caulked. The substrate 111 of the light source unit 11 is fastened to the base 31 of the reflector molded product 30 by such heat caulking. The same applies to the light source unit 12 and the reflector molded product 40, and also to the light source unit 13 and the reflector molded product 50.

  Next, the fastening screw 21 is inserted into the through hole 116 from above the substrate 111, and the fastening screw 21 is fastened to the boss 36, thereby fixing the substrate 111 to the base 31. The same applies to the light source unit 12 and the reflector molded product 40, and also to the light source unit 13 and the reflector molded product 50.

  Next, the assembly of the light source unit 11, the reflector molded product 30, and the fastening screw 21 is temporarily assembled on the table 83. Specifically, the rotary shaft 38 of the reflector molded product 30 is inserted into the bearing hole 838, the guided portion 39 is inserted into the guide hole 839, and the temporary fixing claw 391 is inserted into the guide hole 839 from the top to the bottom of the guide hole 839. Then, the temporary pawl 391 is hooked on the lower surface of the table 83 of the bracket 80. The fastening screw 24 is inserted into the through hole 837 from below the through hole 837, and the fastening screw 24 is temporarily fastened to the boss 37. Similarly, the assembly of the light source unit 12, the reflector molded product 40 and the fastening screw 22 is temporarily assembled on the table 84, and the assembly of the light source unit 13, the reflector molded product 50 and the fastening screw 23 is temporarily assembled on the table 85. To do.

Next, the bracket 80 is fixed to a jig installed in front of the screen. Then, the semiconductor light emitting device 110 is caused to emit light, and the bright portion B1 is projected onto the screen. Then, while measuring the position of the bright part B1 in the screen (in particular, the position of the cut-off line C1) with a tester or the like, the reflector molded product 30 is tilted left and right about the rotation shaft 38. Thus, when the bright part B1 is moved to the left and right and the position of the bright part B1 (particularly, the cut-off line C1) is measured by a tester or the like, the cut-off beam reflector molded product 30 is measured. Stop. Then, the fastening screw 24 is finally tightened to the boss 37 to fix the reflector molded product 30 to the table 83.
Similarly, the assembly of the light source unit 12, the reflector molded product 40 and the fastening screw 22 is fixed to the table 84, and the assembly of the light source unit 13, the reflector molded product 50 and the fastening screw 23 is fixed to the table 85.

According to the above embodiment, the following effects can be obtained.
(1) The reflector 301 of the reflector molded product 30 forms the bright part B1. A clear cut-off line C1 appears on the edge of the bright part B1, and the light intensity distribution of the bright part B1 is required to be strict. When assembling such a reflector molded product 30 to the bracket 80, the position and orientation of the reflector 301 can be adjusted by tilting the reflector 301 about the rotating shaft 38 and the bearing hole 838. Accordingly, the positions of the bright part B1 and the cut-off line C1 in the screen can be adjusted, and the bright part B1 and the cut-off line C1 can be satisfied with strict regulations or standards. In particular, since the cut-off line C1 intersects the horizontal line, it is effective to adjust the left and right positions of the bright part B1 and the cut-off line C1 by tilting the reflector molded product 30 to the left and right.
The same applies to the reflector molded product 40 and the reflector molded product 50. And the relative positional relationship of the bright parts B1-B3 can also be adjusted.

(2) The reflectors 601 to 603 of the reflector molded product 60 form the bright portions B4 to B6, respectively. A clear bright / dark boundary line is not formed at the edges of the bright portions B4 to B6, and the lightness distribution of the bright portions B4 to B6 is not required to be as strict as the bright portions B1 to B3. Even if such reflectors 601 to 603 are integrally formed, there is no adverse effect on the conformity of the bright portions B4 to B6. Moreover, since the reflectors 601 to 603 are integrally formed, the reflectors 601 to 603 can be assembled to the bracket 80 at the same time. Therefore, the assembly process of the vehicle headlamp 1 can be simplified.

(3) When the reflector molded product 60 is assembled to the bracket 80, the position of the reflector molded product 60 cannot be adjusted. Even so, when the reflector molded products 30, 40, 50 are assembled to the bracket 80, if the reflector molded products 30, 40, 50 are tilted to the left and right, depending on the position of the bright portions B 4 to B 6. The positions of the bright portions B1 to B3 can be adjusted. Therefore, the relative positional relationship between the bright portions B4 to B6 and the bright portions B1 to B3 can also be adjusted.

DESCRIPTION OF SYMBOLS 1 Vehicle headlamp 24-26 Fastening screw 30,40,50 Reflector molding 32-35 Crimp protrusion 37 Boss 38 Rotating shaft 39 Guided part 391 Temporary stop claw 80 Bracket 83 Table 110,120,130 Light emitting element 111 Substrate 112-115 Caulking hole 301, 401, 501 Reflector 838 Bearing hole

Claims (7)

A light emitting element;
A reflector that is assembled with the light emitting element and reflects light emitted by the light emitting element;
A rotating shaft integrally formed with the reflector and extending vertically;
The reflector is assembled, and includes a bracket having a bearing portion,
The rotating shaft is pivotally supported by the bearing portion;
A vehicle headlamp, wherein the reflector is fastened to the bracket. A base integrally formed with the reflector;
A boss formed integrally with the base so as to protrude from the base;
The rotating shaft is integrally formed with the base so as to protrude from the base in the same direction as the boss,
The protruding end surface of the boss abuts on the bracket, and the boss supports the base and the bracket so as to be separated from each other.
The vehicle headlamp according to claim 1, wherein the bracket is fastened to the boss. A guided portion integrally formed on the base so as to protrude from the base in the same direction as the boss;
The bracket has a guide hole formed in the bracket so as to have an arc shape centered on the bearing portion;
The vehicle headlamp according to claim 2, wherein the guided portion is inserted into the guide hole. A claw formed in a convex shape on the guided portion so as to be integrated with the guided portion;
The vehicle headlamp according to claim 3, wherein the claw is caught by the bracket around the guide hole. Further comprising a substrate on which the light emitting element is surface-mounted,
The vehicular headlamp according to any one of claims 2 to 4, wherein the substrate abuts on the base on the opposite side of the boss, and the substrate is fastened to the base by thermal caulking. light. The vehicle headlamp according to claim 5, wherein the substrate is fastened to the base with a screw. A light emitting element;
A reflector that is assembled with the light emitting element and reflects light emitted by the light emitting element;
In a method for manufacturing a vehicle headlamp comprising a bracket to which the reflector is assembled,
The rotary shaft that is integrally formed with the reflector and extends vertically is pivotally supported on a bearing portion formed on the bracket,
Next, the light emitting element is caused to emit light, and the light of the light emitting element is reflected by the reflector, thereby projecting a bright part of the reflected light onto the screen and tilting the reflector left and right about the rotation axis. To adjust the position of the bright part in the screen,
Next, the manufacturing method of the vehicle headlamp characterized by fastening the said reflector to the said bracket.

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