JP2017010639A - Vehicle headlamp - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a vehicle headlamp capable of suppressing the influence of transfer of heat from a light source to optical members while dissipating the heat generated by the light source, and reducing a relative position deviation between the light source and a resin optical member caused by heat from an engine and the light source.SOLUTION: A metal lamp unit 10 comprises light sources 10-1, etc. Each of the light sources 10-1, etc. comprises: a metal heat sink 11 configured from a base section 11a and a radiation fin 11b; a metal base section 12, a pedestal 13, and an LED element 14. A resin bracket 20 includes openings 21-1, etc. through which the pedestals 13 of the respective light sources are passed, and includes screws 22 disposed on both sides of each opening for fixing the resin bracket 20 to screw holes 12a of the base sections 12 of the light sources 10-1, etc. Lenses 31 and 32 are formed on a resin integral lens 30. Screws 33 corresponding to screw holes 23 of the resin bracket 20 are provided on both ends of the resin integral lens 30, respectively, so that the resin integral lens 30 is fixed to the resin bracket 20.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a vehicle headlamp.

  A conventional vehicle headlamp includes a metal bracket that holds a metal heat sink and a light source facing each other, and a resin optical member for condensing light from the light source, for example, a resin integrated lens. (Reference: Patent Document 1). In the case of a traveling beam (high beam), a resin integral lens using a 1 mm square light source concentrates around a front half-width of about 5 ° in the vicinity of the front center and exhibits maximum luminous intensity, while in the case of a passing beam (low beam), A cut-off line is formed near the front horizontal line, and an elbow that connects the cut-off line to the front center is formed by further controlling the cut-off line downward by about 0.57 ° so as not to give glare to the oncoming lane side vehicle. Further, heat generated from the light source is dissipated from the metal heat sink and the metal bracket.

JP, 2014-110213, A Japanese Patent No. 5378558 (Japanese Patent Laid-Open No. 2012-1422934)

In the above-described conventional vehicle headlamp, the metal bracket and the resin integrated lens are thermally expanded by heat from the engine and the light source. At this time, the optical standard of each light source is determined from the difference in the coefficient of thermal expansion. And the corresponding optical reference of the resin integrated lens are shifted from each other. For example, if the metal bracket is formed of the aluminum alloy ADC12, the coefficient of thermal expansion is 2.1 × 10 ⁻⁵ K. On the other hand, if the resin integrated lens is formed of polycarbonate, the coefficient of thermal expansion is 6. There are 3 times the thermal expansion coefficient of 5 × 10 ⁻⁵ K and ADC12, and if the total length of the light source is 120 mm, the optical reference of each light source and the resin optical member The relative positional deviation from the corresponding optical reference becomes a maximum of 0.74 mm. As a result, in the case of a traveling beam (high beam), there is a problem that the position of the maximum luminous intensity near the front center is shifted by about 0.75 ° and the distance visibility is deteriorated. Further, in the case of a passing beam (low beam), there is a problem in that the position of the elbow is shifted and glare is given to the oncoming vehicle, and the position of the maximum luminous intensity is shifted similarly to the traveling beam (high beam). Furthermore, there is also a problem that the light distribution is disturbed due to the occurrence of stress in the holding portion between the light source and the resin-made integrated lens, resulting in deformation or cracking.

  In order to solve the above-described problem, a vehicle headlamp according to the present invention includes a plurality of light sources, a resin bracket that fixes the plurality of light sources, and a resin optical member that is fixed to the resin bracket. Each light source includes a metal member and a semiconductor light emitting element fixed to the metal member, and the resin optical member is an integrally formed optical member that controls light distribution of all light from the light source. is there.

  The at least two fixing means for fixing between the light source and the resin bracket are positioned on a straight line in the longitudinal direction of the resin bracket passing through the center of the light source as viewed from the front of the vehicle, or passing through the center of the light source. It lies on a vertical line that is perpendicular to the longitudinal line of the bracket and passes through the center of the light source. Thus, the light source does not rotate regardless of the difference in thermal expansion between the metal member and the resin bracket due to temperature, and is held at a constant angle in the longitudinal direction of the resin bracket.

  In addition, the vehicle lighting device includes a light source, a resin bracket having an opening for holding the light source, and a resin optical member, and the resin optical member is held by the resin bracket (see: Patent Document 2). However, this vehicular illumination device is not a headlamp but a rear lamp (marker lamp), and therefore does not receive heat from the engine and has a small light source output. As a result, the above-mentioned problem does not occur, and it is not necessary to hold the light source on the metal member with the heat sink.

  According to the present invention, the difference in the coefficient of thermal expansion between the resin bracket and the resin optical member is reduced, and accordingly, the relative positional deviation between the light source and the resin optical member due to heat from the engine and the light source is reduced. it can. As a result, in the case of a traveling beam (high beam), there is no shift in the position of the maximum luminous intensity near the center of the front, and it is possible to suppress a decrease in distance visibility, and in the case of a passing beam (low beam), there is no shift in the elbow position, Accordingly, it is possible to suppress the shift in the position of the maximum luminous intensity without giving glare to the oncoming vehicle, similarly to the traveling beam (high beam). Furthermore, it is possible to prevent the light distribution from being disturbed by suppressing deformation or cracking due to the generation of stress in the holding portion between the light source and the resin optical member. Further, since the light source is radiated by the metal member, the light source output can be increased. Furthermore, since the light source and the resin optical member are not directly touched and insulated by the low thermal conductive resin bracket, the resin optical member is not easily deformed by heat.

BRIEF DESCRIPTION OF THE DRAWINGS The 1st Embodiment of the vehicle headlamp which concerns on this invention is shown, (A) is a decomposition | disassembly top view, (B) is a disassembled perspective view. It is a figure explaining the position of the screw of the resin-made brackets of FIG. It is a perspective view after the assembly of the vehicle headlamp of FIG. 3A and 3B show details of FIG. 3, in which FIG. 3A is a top view, FIG. 3B is a front view, and FIG. The 2nd Embodiment of the vehicle headlamp which concerns on this invention is shown, (A) is a decomposition | disassembly top view, (B) is a lower view disassembled perspective view. It is a perspective view after the assembly of the vehicle headlamp of FIG. FIG. 6 shows details of FIG. 6, (A) is a top view, (B) is a front view, and (C) is a sectional view taken along the line CC of (B). 3 shows a third embodiment of a vehicle headlamp according to the present invention, (A) is an exploded top view, and (B) is an exploded perspective view. FIG. It is a perspective view after the assembly of the vehicle headlamp of FIG. FIG. 9 shows details of FIG. 9, (A) is a top view, (B) is a front view, and (C) is a sectional view taken along the line CC of (B). 4 shows a fourth embodiment of a vehicle headlamp according to the present invention, (A) is an exploded top view, and (B) is an exploded perspective view. FIG. It is a perspective view after the assembly of the vehicle headlamp of FIG. The details of FIG. 12 are shown, (A) is a top view, (B) is a front view, and (C) is a sectional view taken along the line CC of (B).

  FIG. 1 shows a first embodiment of a vehicle headlamp according to the present invention, in which (A) is an exploded top view and (B) is an exploded perspective view.

  In FIG. 1, 10 is a metal lamp unit, 20 is a resin bracket, and 30 is a resin integral lens. That is, the vehicular headlamp of FIG. 1 is a direct projection type that projects with the resin integrated lens 30 with the light source as a focal point.

  The metal lamp unit 10 includes light sources 10-1, 10-2, ..., 10-7. Each of the light sources 10-1, 10-2,..., 10-7 is fixed on the metal heat sink 11, the metal base 12, the pedestal 13 and the pedestal 13, for example, 1 mm square. Light emitting diode (LED) element 14. The pedestal 13 may be a metal or an insulating material. Further, the base portion 11a and the metal base portion 12 may be integrated. The light sources 10-1, 10-2,..., 10-7 are divided into two groups by a resin integrated lens 30 described later. That is, the light sources 10-1, 10-3, 10-5, and 10-7 are combined with a high beam / low beam, and the light sources 10-2, 10-4, and 10-6 between them are dedicated to the high beam.

  The resin bracket 20 has openings 21-1, 21-2,..., 21-7 through which the bases 13 of the light sources 10-1, 10-2,. -1, 21-2,..., 21-7 are screw holes for fixing the resin bracket 20 to the screw holes 12a of the base portion 12 of the light sources 10-1, 10-2,. It has a screw 22 provided. Note that at least two screws 22 as fixing means are provided for each of the light sources 10-1, 10-2,.

  As shown in FIG. 2A, the screw 22 is positioned on a longitudinal straight line L1 passing through the center C of the openings 21-1, 21-2,. Alternatively, as shown in FIG. 2 (B), it is positioned on a vertical line L2 passing through the center C of the openings 21-1, 21-2,. Thereby, even if the resin bracket 20 expands and contracts in the longitudinal direction, the light sources 10-1, 10-2,..., 10 of the base 13 fitted in the openings 21-1, 21-2,. -7 does not rotate. Therefore, the light sources 10-1, 10-2,..., 10-7 are held at a constant angle in the longitudinal direction of the resin bracket 20 regardless of the temperature.

  Returning to FIG. 1, the resin integrated lens 30 includes four lenses 31 having wide light distribution characteristics corresponding to the light sources 10-1, 10-3, 10-5, and 10-7 as light sources for high beam / low beam. Three lenses 32 having narrow light distribution characteristics corresponding to the light sources 10-2, 10-4, and 10-6 as high beam dedicated light sources are formed. Screws 33 provided in screw holes corresponding to the screw holes 23 of the resin bracket 20 are provided at both ends of the resin integrated lens 30, and the resin integrated lens 30 is fixed to the resin bracket 20 by the screws 33. Being held.

  3 is a perspective view after the vehicle headlamp of FIG. 1 is assembled, FIG. 4 is a detailed view of FIG. 3, (A) is a top view, (B) is a front view, and (C) is (B). It is CC sectional view taken on the line.

  As shown in FIGS. 3 and 4, the light source is obtained by inserting the screw 22 (see FIG. 1) of the resin bracket 20 into the screw hole 12a of the base 12 of each light source 10-1, 10-2,. 10-1, 10-2,..., 10-7 are fixedly held on the resin bracket 20. Next, the resin integrated lens 30 is fixedly held on the resin bracket 20 by inserting the screw 33 of the resin integrated lens 30 into the screw hole 23 of the resin bracket 20. The mounting surfaces of the light sources 10-1, 10-2,..., 10-7, the resin bracket 20 and the resin integrated lens 30 of the metal lamp unit 10 are perpendicular to the vehicle front direction. Since the difference in coefficient of thermal expansion between the resin bracket 20 and the resin integrated lens 30 is small, the stress at the holding portion formed by the screw hole 23 and the screw 33 between the resin bracket 20 and the resin integrated lens 30 is small. The occurrence of deformation or cracking is suppressed. Further, in the light sources 10-1, 10-2,..., 10-7, since no resin exists between the base 13 and the heat sink 11, the heat dissipation efficiency of the heat sink 11 is high.

  5A and 5B show a second embodiment of a vehicle headlamp according to the present invention, in which FIG. 5A is an exploded top view and FIG. 5B is a bottom exploded perspective view.

  In FIG. 5, 10 'is a metal lamp unit, 20 is a resin bracket, and 30' is a resin integrated reflector. That is, the vehicle headlamp of FIG. 5 is a reflector type that projects with the resin integrated reflector 30 ′ with the light source as a focal point.

  The light source 10'-1, 10'-2,..., 10'-7 pedestal 13 'of the lamp unit 10' corresponds to the light sources 10-1, 10-2, ... 10-7 of the lamp unit 10 of FIG. Unlike the base 13, the LED element 14 'on the base 13' is configured to face upward. The light sources 10'-1, 10'-2, ..., 10'-7 are divided into two groups by a resin integrated reflector 30 'described later. That is, the light sources 10'-1, 10'-3, 10'-5, 10'-7 are combined with a high beam / low beam, and the light sources 10'-2, 10'-4, 10'-6 between them are For high beam only.

  The resin bracket 20 has openings 21-1, 21-2,..., 21-7 for penetrating the pedestals 13 ′ of the light sources 10′-1, 10′-2,. Further, the base portions 12 of the light sources 10′-1, 10′-2,..., 10′-7 are coupled to the resin bracket 20 on both sides of the openings 21-1, 21-2,. It has the same screw 22 as in the case of FIG.

  The resin integrated reflector 30 ′ includes four reflectors 31 ′ corresponding to the light sources 10′-1, 10′-3, 10′-5, and 10′-7 as high beam / low beam combined light sources, and a high beam dedicated light source. Three reflectors 32 'corresponding to the light sources 10'-2, 10'-4, 10'-6 are formed. Screws 33 provided in screw holes corresponding to the screw holes 23 of the resin bracket 20 are provided at both ends of the resin integrated reflector 30 ′, and the resin integrated reflector 30 ′ is made of resin brackets by the screws 33 ′. 20 is fixed and held.

  6 is a perspective view after assembly of the vehicle headlamp of FIG. 5, FIG. 7 shows details of FIG. 6, (A) is a top view, (B) is a front view, and (C) is (B). It is CC sectional view taken on the line.

  As shown in FIGS. 6 and 7, the screw 22 of the resin bracket 20 is inserted into the screw hole 12a (see FIG. 5) of the base 12 of each light source 10′-1, 10′-2,..., 10′-7. Thus, the light sources 10′-1, 10′-2,..., 10′-7 are fixedly held on the resin bracket 20, and then the screw holes 23 of the resin bracket 20 by the screws 33 ′ of the resin integrated lens 30 ′. The resin integrated reflector 30 ′ is fixedly held on the resin bracket 20. The mounting surfaces of the respective light sources 10′-1, 10′-2,..., 10′-7, the resin bracket 20 and the resin integrated reflector 30 ′ of the metal lamp unit 10 ′ are perpendicular to the vehicle front direction. ing. Since the difference in coefficient of thermal expansion between the resin bracket 20 and the resin integrated reflector 30 ′ is small, the stress at the holding portion formed by the screw hole 23 and the screw 33 ′ between the resin bracket 20 and the resin integrated reflector 30 ′ is Small deformation or cracking is suppressed. Further, in the light sources 10'-1, 10'-2, ..., 10'-7, since no resin exists between the base 13 'and the heat sink 11, the heat dissipation efficiency of the heat sink 11 is high.

  8A and 8B show a third embodiment of a vehicle headlamp according to the present invention, wherein FIG. 8A is an exploded top view and FIG. 8B is an exploded perspective view.

  In FIG. 8, 10 "is a metal lamp unit, 20 is a resin bracket, and 30 is a resin integrated lens. In other words, the vehicle headlamp of FIG. This is a projector type that projects at 30.

  A light source 10 ″ -1, 10 ″ -2,..., 10 ″ -7 of the lamp unit 10 ″ is individually provided with an LED element 14 ′ facing upward and reflecting light from the LED element 14 ′. A reflector 15 'is provided.

  9 is a perspective view after assembly of the vehicle headlamp of FIG. 8, FIG. 10 shows details of FIG. 9, (A) is a top view, (B) is a front view, and (C) is a view of (B). It is CC sectional view taken on the line.

  9 and 10, each light source 10 "-1, 10" -2, ..., 10 "-7 is fixedly held on the resin bracket 20. Next, the screw 33 of the resin integrated lens 30 is made of resin. The resin integrated lens 30 is fixedly held by the resin bracket 20 by being inserted into the screw holes 23 (see FIG. 8B) of the bracket 20. In particular, as shown in FIG. The light from 'is reflected by the individual reflector 15' and collected at one focal point, and then directed to the lens 31 or 32 of the resin integrated lens 30. The other parts are the same as the vehicle headlamp of FIG. .

  11A and 11B show a fourth embodiment of a vehicle headlamp according to the present invention, in which FIG. 11A is an exploded top view and FIG. 11B is an exploded perspective view.

  In FIG. 11, a resin extension 40 is added to the components shown in FIG. That is, the resin integrated lens 30 is held by the resin extension 40, and the resin extension 40 is held by the resin bracket 20. For this reason, the screw hole and the screw 33 provided in the resin integrated lens 30 are transferred to the resin extension 40.

  12 is a perspective view after assembly of the vehicle headlamp of FIG. 11, FIG. 13 shows details of FIG. 12, (A) is a top view, (B) is a front view, and (C) is (B). It is CC sectional view taken on the line.

  As shown in FIG. 12 and FIG. 13, by inserting the screw 22 (see FIG. 11) of the resin bracket 20 into the screw hole 12a of the base 12 of each light source 10-1, 10-2,. 10-1, 10-2,..., 10-7 are fixedly held on the resin bracket 20. Next, the resin integrated lens 30 is accommodated in the resin extension 40, and the resin integrated lens 30 is inserted through the resin extension 40 by inserting the screw 33 of the resin extension 40 into the screw hole 23 of the resin bracket 20. Then, the resin bracket 20 is fixedly held. Also in this case, the mounting surfaces of the light sources 10-1, 10-2,..., 10-7, the resin bracket 20 and the resin integrated lens 30 of the metal lamp unit 10 are perpendicular to the vehicle front direction. Yes. Since the difference in coefficient of thermal expansion between the resin bracket 20 and the resin integral lens 30 is small, the stress at the holding portion formed by the screw hole 23 and the screw 33 between the resin bracket 20 and the resin extension 40 is small. The occurrence of deformation or cracking is suppressed.

  The resin of the resin bracket, the resin optical member, and the resin of the resin extension in the above-described embodiment are preferably the same because there is no difference in thermal expansion coefficient, but may be different. In this case, for example, the thermal expansion coefficient ratio may be 0.5 to 2 times.

  In addition, this invention is applicable also to other semiconductor light emitting elements other than an LED element. Further, by using a resin bracket made of a material having a heat resistant temperature higher than that of the resin optical member, it becomes difficult to be deformed by heat transfer from the metal member, so that the output of the light source can be increased.

  Further, the present invention can be applied to any change in the obvious range of the above-described embodiment. For example, it can be applied to a light distribution adjusting mechanism by holding the resin bracket so as to be tiltable with respect to the lamp housing.

10, 10 ', 10 ": Support legs 10-1, 10-2, ..., 10-7; 10'-1, 10'-2, ..., 10'-7;10" -1, 10 "-2 10 ″ -7: Light source 11: Heat sink 11a: Base portion 11b: Radiation fin 12: Base portion 12a: Screw hole 13, 13 ′: Base 14, 14 ′: LED element 15 ′: Individual reflector 20: Made of resin Brackets 21-1, 21-2,..., 21-7: Opening 22: Screw (fixing means)
23: Screw hole 30: Resin integrated lens 30 ': Resin integrated reflector 31: High beam / low beam combined lens 31': High beam / low beam combined reflector 32: High beam dedicated lens 32 ': High beam dedicated reflector 33, 33': Screw 40 : Resin extension L1: Longitudinal straight line L2: Vertical line

Claims (9)

Multiple light sources;
A resin bracket for fixing the plurality of light sources;
Comprising a resin optical member fixed to the resin bracket;
Each light source includes a metal member and a semiconductor light emitting element fixed to the metal member,
The resin optical member is a vehicle headlamp that is an integrally formed optical member that controls light distribution of all light from the light source.   The vehicle headlamp according to claim 1, wherein the resin bracket has an opening, and each of the light sources is fixed to the opening.   The at least two fixing means for fixing between the light source and the resin bracket are located on a straight line in the longitudinal direction of the resin bracket passing through the center of the light source when viewed from the front of the vehicle. Vehicle headlamp.   At least two fixing means for fixing between the light source and the resin bracket are perpendicular to the longitudinal straight line of the resin bracket passing through the center of the light source as viewed from the front of the vehicle and passing through the center of the light source. The vehicle headlamp according to claim 1, which is located on a line.   The vehicle headlamp according to claim 1, wherein the resin optical member is a resin integral lens.   The vehicle headlamp according to claim 1, wherein the resin optical member is a resin integrated reflector.   The vehicle headlamp according to claim 5, wherein the light source includes an individual reflector.   The vehicle headlamp according to claim 1, further comprising a resin extension that covers the resin optical member, wherein the resin optical member is held by the resin bracket via the resin extension. The vehicular headlamp according to any one of claims 1 to 8, wherein the resin bracket has a heat resistant temperature higher than that of the resin optical member.

Images