JP4192806B2 - Projector type vehicle lamp - Google Patents

Description

  The present invention relates to a projector-type vehicular lamp that uses an LED (light emitting diode) as a light source, for example, applied as a headlamp.

  FIG. 11 shows this type of projector-type vehicle lamp 100 (see, for example, Patent Document 1). The vehicular lamp 100 includes a light source bulb 2 provided in the vicinity of the first focal point of the concave mirror 1 and a light beam emitted from the light source bulb 2 and reflected by the concave mirror 1 so as to adjust the light beam to a substantially parallel light beam and forward the lamp. It is generally configured with a convex lens 3 that emits light.

  Specifically, in the vehicular lamp 100, a shade 4 is provided between the light source bulb 2 and the convex lens 3, and a light distribution pattern having a cut line suitable as a passing beam can be obtained by the shade 4. .

  The light source bulb 2 is mounted with its filament positioned at the first focal point of the concave mirror 1 and its electrical connection portion fitted into the cylindrical opening 1a. A frame 5 is attached to the open end of the concave mirror 1, and a convex lens 3 is fixed to the frame 5 and a shade 4 is supported.

  Further, as shown in FIG. 12, the vehicular lamp 100 includes a ventilation hole 1b immediately above the cylindrical opening 1a for mounting the light source bulb 2 of the concave mirror 1, and a ventilation hole 1b below the nearest. Each of the through holes 1c is provided.

The vehicle lamp 100 has a high temperature around the light source bulb 2 when it is turned on, but the heat is dissipated by heat convection generated between the through holes 1b and 1c, so that the temperature rise around the light source bulb 2 is suppressed. Is done.
A microfilm of Japanese Utility Model No. 4-76322

  However, in the vehicular lamp 100, since the light emitted from the light source bulb 2 has high thermal energy, the convex lens 3 has to be formed of glass, and therefore has the problem of increasing the weight of the lamp. ing.

  In the vehicular lamp 100, for example, the concave mirror 1 is formed of an aluminum vapor deposition plate, resin, or iron plate, the convex lens 3 is formed of glass, and the shade 4 is formed of an aluminum vapor deposition plate or iron plate. The frame 5 is formed of an aluminum vapor deposition plate. Thus, since the material used for each part of the vehicle lamp 100 is different, it is necessary to make each part separately and to assemble these parts, but the dimension in the optical axis direction that requires accuracy is required. However, there is a problem that the variation in the light distribution performance is increased due to the variation in the assembly (Assy) and the variation in component dimensions.

  Further, the vehicular lamp 100 has a problem that it has a large number of parts, which complicates parts management, increases the number of assembling steps, and increases the cost.

  Furthermore, the vehicular lamp 100 has a problem that the reflection performance near the center of the concave mirror 1 provided with the through holes 1b and 1c is lowered, and the illuminance of the hot zone at the center of the light distribution pattern is lowered. Also have.

  Therefore, the present invention can reduce the weight of the lamp and reduce the number of parts, can stably obtain excellent light distribution performance, and can maximize the reflection performance of the concave mirror to provide the light distribution pattern. An object of the present invention is to provide a projector-type vehicular lamp capable of obtaining sufficient illuminance in the hot zone.

In order to achieve the above-mentioned object, the invention according to claim 1 adjusts a light source provided in the vicinity of the first focal point of the concave mirror and a light beam emitted from the light source and reflected by the concave mirror into a substantially parallel light beam. A projector-type vehicular lamp that includes a convex lens that emits light and emits in front of the lamp,
The light source has one light emitting portion facing the small concave mirror in the vicinity of the first focal point of the small concave mirror formed on each of a plurality of small reflectors as a free-form surface based on a spheroidal curved surface or a rotational ellipse. It consists of multiple LEDs that are set one by one,
The small reflector and the small convex lens that covers the opening of the small reflector are formed of the same transparent resin material with the same coefficient of thermal expansion ,
The small reflector includes an upper reflector formed integrally with the upper fixed portion of the small convex lens, the small concave mirror, and a light source fixed portion, and a lower fixed portion of the small convex lens and a shade formed integrally with the upper reflector. A lower reflector coupled from the lower side,
The upper reflector and the lower reflector are coupled to each other, the small convex lens is fixed by the upper fixing portion and the lower fixing portion, and the LED is fixed to the light source fixing portion so as to be small for each small reflector. Construct a projector-type lamp
A plurality of small projector lamps composed of the plurality of small reflectors are incorporated in one housing.

  Therefore, according to the first aspect of the present invention, the light of the LED is emitted toward the small concave mirror for each small projector lamp, and is reflected by the small concave mirror to reach the small convex lens and passes through the small convex lens. By doing so, the light can be adjusted to a parallel light beam and emitted to the front of the vehicular lamp, thereby producing a desired light distribution pattern.

  In addition, since the LED applied as the light source is small in size, it can save the space required for mounting, and the thermal energy of the emitted light is also smaller than that of the light source with filament, so that the excessive temperature of the lamp chamber The rise can be avoided, and the small convex lens and the small reflector can be made of resin.

  In addition, since the small convex lens and the small reflector are made of resin, they can be formed with higher dimensional accuracy than using an iron plate or an aluminum vapor deposition plate.

  In addition, the upper fixed part of the small convex lens, the small concave mirror, and the light source fixing part are integrally formed on one upper reflector constituting the small reflector, and the lower fixed part of the small convex lens is fixed on the other lower reflector. Since the part and the shade are integrally formed, the relative positions of the small convex lens, the small concave mirror, the LED, and the shade, which are important in optical positional relationship, can be determined with high accuracy.

Further, since the small convex lens and the small reflector are formed with the same coefficient of thermal expansion, the occurrence of distortion due to thermal deformation can be avoided as much as possible.

The invention according to claim 2 is the projector-type vehicle lamp according to claim 1 ,
The upper and lower reflectors are formed by depositing aluminum on the inner surfaces thereof.

For this reason, in the invention described in claim 2 , since the upper and lower reflectors are formed of a transparent resin material, the aluminum vapor-deposited layer on the inner surface is visible from the outside as if it had a metal decoration on the outer side. Can do.

  As described above in detail, according to the invention described in claim 1, since the LED applied as the light source is small in size, the space required for mounting can be saved and the small reflector can be downsized. And since the thermal energy of the emitted light is also smaller than the light source with filament, it is possible to avoid an excessive temperature rise in the lamp chamber and to make the small convex lens and the small reflector made of resin. Can be reduced in size and weight.

  In addition, according to the first aspect of the present invention, since it is not necessary to make a hole for ventilation in the small concave mirror, the reflective performance of the small concave mirror is maximized, and sufficient illuminance of the hot zone of the light distribution pattern is obtained. As a result, the visibility of the traveling lane can be improved.

  According to the first aspect of the present invention, the relative positions of the optically important small convex lens, the small concave mirror, the LED, and the shade can be determined with high accuracy. In addition, it is possible to form a small projector lamp having a stable quality.

  Furthermore, according to the first aspect of the present invention, since the number of parts is small, parts management is easy and can be easily assembled, and as a result, cost can be reduced.

According to the invention described in claim 1 , since the small convex lens and the small reflector are formed with the same thermal expansion coefficient, it is possible to avoid the occurrence of distortion due to thermal deformation as much as possible. The optically superior characteristics of the lamp can be maintained over a long period of use.

According to the invention of claim 2 , since the upper and lower reflectors constituting the small reflector are formed of a transparent resin material, in addition to the effect of the invention of claim 1 , the aluminum vapor deposition layer on the inner surface is It can be visually recognized from the outside as if it had a metal decoration on the outside, and as a result, the appearance can be improved.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. In addition, the component which show | plays the same function as what was disclosed by FIG. 11, FIG. 12 attaches | subjects and demonstrates the same code | symbol.

  1 to 3 show a projector type vehicle lamp A according to the present invention. The vehicular lamp A is generally configured by incorporating a plurality of small projector lamps 10a, 10b, 10c, 10d, 10e, 10f, 10g, 10h, 10i, 10j into a single housing 20 using the LED 11 as a light source. Has been. Note that the small projector type lamp is denoted by reference numeral 10 in the following representative examples.

  The housing 20 includes a casing 22 having an opening at the front and a through glass 21 that covers the opening of the casing 22. The plurality of small projector lamps 10 a to 10 j are incorporated in the housing 20 by being fixed to the casing 22 via the fixture 23. At this time, the fixture 23 is supported by the casing 22 so that the optical axes of the plurality of small projector lamps 10a to 10j can be adjusted vertically and horizontally by two adjusting screws and a pivot structure (not shown). . In FIGS. 1 and 2, reference numerals 26 and 27 denote a clearance lamp and a front turn lamp, respectively.

  Further, the small projector lamps 10a to 10j are designed so that, for example, the following light distribution pattern is obtained depending on the mounting position.

  6A and 6B show the light distribution pattern, where FIG. 6A is a horizontal diffusion type (first light distribution pattern), FIG. 6B is a condensing flat type (second light distribution pattern), and FIG. 6C is a cut line of a low beam. The horizontal diffusion type (third light distribution pattern) having (3) and (d) show the condensing flat type (fourth light distribution pattern) having the cut line of the passing beam, respectively.

  Among the small projector-type lamps 10a to 10j, the small projector-type lamps 10a, 10c, 10d, and 10g are designed so as to obtain a third light distribution pattern (see FIG. 6C). 10e and 10f are designed to obtain a fourth light distribution pattern (see FIG. 6D), and the small projector-type lamps 10h, 10i, and 10j use the first light distribution pattern (see FIG. 6A). ). In general, the vehicular lamp A can produce the light distribution pattern LP suitable for the low beam shown in FIG.

  Specifically, in the vehicular lamp A, as shown in FIG. 7, the light source is a rotating concave curved surface 7 or a free curved surface based on a rotating ellipse formed on each of the plurality of small reflectors 14. In the vicinity of one focal point F1, it is composed of a plurality of LEDs 11 (see FIGS. 4 and 5) that are set one by one with the light emitting portion 11a facing the small concave mirror 7.

  As shown in FIGS. 4 and 5, the LED 11 is fixed to the mounting plate 9 and is sub-assembled, and the mounting plate 9 is attached to the light source fixing portion 19 provided in the substantially half of the rear side of the upper reflector 12 with a screw 24. By being coupled, the light emitting portion 11a is attached to face the small concave mirror 7. 4 and 5, reference numeral 25 denotes four lead wires, two of which are the lead wires of the LED 11, and the other two are for the cooling element.

  In the present embodiment, the LED 11 is installed with its light emitting portion 11a arranged in a direction substantially orthogonal to the optical axis Z of the lamp 10 passing through the central portion of the small convex lens 6 and the first focal point F1. FIG. 8 shows an emission pattern L0 of light emitted from the light emitting portion 11a of the LED 11, and a broken line in FIG. 7B shows an incident state of the light of the emission pattern L0 on the small concave mirror 7. .

The small projector-type lamp 10 includes a small reflector 14 made of a first resin material having an opening on the front side, and a small convex lens made of a second resin material that covers the front opening of the small reflector 14 and constitutes a lamp chamber 14a. 6. At this time, as the first resin material, polycarbonate resin, acrylic resin, is used as the second resin material, polycarbonate resin, acrylic resin, is used.

  7 and 10, the small reflector 14 includes an upper reflector 12 in which an upper fixing portion 15 a of the small convex lens 6, a small concave mirror 7, and a light source fixing portion 19 are integrally formed, and a lower portion of the small convex lens 6. The side fixing portion 16a and the shade 4 are integrally formed, and the lower reflector 13 that is coupled to the upper reflector 12 from below is formed.

  The upper reflector 12 has a small concave mirror 7 formed on the rear side thereof, a light source fixing portion 19 formed on the back surface side of the flange portion 12a on both sides of the small concave mirror 7, and a small portion that is continuous with the front end portion of the small concave mirror 7. An upper casing portion 15 having a diameter larger than that of the concave mirror 7 is formed, and an upper fixing portion 15a is formed in a groove shape along the inner periphery of the front end of the upper casing portion 15, and a reflecting member is provided on the inner surface. The whole structure is formed by vapor deposition. The light source fixing portion 19 is formed as a protrusion having a screw hole at the center. By fixing the sub-assembly member of the LED 11 to the upper reflector 12 via the light source fixing portion 19, the light emitting portion 11 a of the LED 11 is positioned in the vicinity of the first focal point F 1 of the small concave mirror 7.

  The lower reflector 13 includes the shade 4 and the lower casing portion 16. The shade 4 has an inverted L-shaped cross section and is erected on the rear end portion of the lower casing portion 16. The upper bent edge portion 4 a is formed along the meridional image plane. The upper side portion 4b is formed in a similar shape to the cut line CL in FIG. 9 or on a flat surface in accordance with the first to fourth light distribution patterns in FIG. A lower fixing portion 16a is formed in a groove shape along the inner periphery of the front end portion of the lower casing portion 16. Further, the lower reflector 13 is entirely configured by depositing a reflective member on the inner surface including the shade 4 (including the upper surface of the upper side portion 4b).

  Then, as shown in FIGS. 4, 7, and 10, the small reflector 14 is joined by the coupling means with the two flanges 12a and 13a formed on the outer peripheral portions of the reflectors 12 and 13 being brought into contact with each other. Consists of. As a result, the small reflector 14 has a substantially half portion on the front side having a closed cross section by the casing parts 15 and 16, and a substantially half portion on the rear side has a substantially semicircular cross section only by the small concave mirror 7 of the upper reflector 12. The shade 4 that is configured and provided integrally with the lower reflector 13 is located in the vicinity of the second focal point F <b> 2 of the small concave mirror 7.

  The coupling means at this time includes a screw 8, a screw hole 17 drilled in the flange portion 12 a of the upper reflector 12, and a coupling boss portion 18 provided integrally with the lower reflector 13. The screws 12 and 13 can be coupled by passing through the screw hole 17 (see FIG. 7A) and screwing it into the coupling boss 18 (see FIG. 4).

  The small convex lens 6 has a thin-walled outer peripheral flange portion 6a, and when the reflectors 12 and 13 are coupled, the outer peripheral flange portion 6a is fitted to the both fixed portions 15a and 16a. Attached.

  As shown in FIG. 7, in the small reflector 14 configured as described above, the front lamp chamber 14a is formed by the small convex lens 6, the upper casing portion 15, and the lower casing portion 16, and the rear lamp chamber 14b is small. The concave mirror 7 and the upper side 4b of the shade 4 that partially covers the lower part of the front side of the small concave mirror 7 and a sub-assembly member of the LED 11 fixed to the light source fixing part 19 are formed.

  The small projector type lamp 10 is an open portion of the substantially semicircular cross section of the small reflector 14, and the entire structure is obtained by fixing the sub-assembly of the LED 11 to the upper reflector 12 via the light source fixing portion 19. Is done. By this fixing, the light emitting part 11a of the LED 11 is positioned in the vicinity of the first focal point F1 of the small concave mirror 7.

  The vehicular lamp A according to the present embodiment includes a plurality of small projector lamps 10a to 10j formed of the small projector lamp 10, and as shown in FIGS. 3 and 4, the first fixture 23a, Using the fixture 23 consisting of the second fixture 23b and the third fixture 23c as appropriate, the small convex lens 6 is made to face the transparent glass 21, and the upper and lower reflectors 12 and 13 are on the upper side and the lower side, respectively. And attached to the casing 22.

  The light L of the LED 11 in the vehicular lamp A is emitted from the light emitting portion 11a toward the reflecting surface of the small concave mirror 7 and reflected by the reflecting surface of the small concave mirror 7 as shown in FIG. The light is condensed on the shade 4 formed at the position of the second focal point F2 of the small concave mirror 7, and a part of the collected light is blocked by the shade 4 and the other part is reflected by the upper side part 4b. The light of the portion becomes a light distribution pattern having a cut line, and is projected in front of the vehicular lamp A. The reflection at the upper side 4b contributes to the improvement of the illuminance of the light projection.

  FIG. 9 shows the light distribution pattern LP at this time, and this light distribution pattern LP is suitable as a beam for passing due to the formation of the cut line CL. In addition, since it is not necessary to make a hole for adjusting the temperature in the small concave mirror 7, the reflective performance of the small concave mirror 7 can be maximized, and coupled with the reflection of the upper side 4 b, Illuminance can be improved.

  Further, since the LED 11 applied as a light source is small in size, the space required for mounting can be saved and the small reflector 14 can be miniaturized, and the thermal energy of the emitted light L is also a light source with a filament (FIG. 11). Therefore, it is possible to avoid an excessive temperature rise in the lamp chamber and to make the small convex lens 6 and the small reflector 14 made of resin. Can be reduced.

  In addition, since the small convex lens 6 and the small reflector 14 are made of resin, they can be formed with higher dimensional accuracy than using an iron plate or an aluminum vapor deposition plate.

  Also, one upper reflector 12 constituting the small reflector 14 is integrally formed with an upper fixing portion 15 a of the small convex lens 6, a small concave mirror 7, and a light source fixing portion 19, and the other lower reflector 13 is provided with the other upper reflector 12. Since the lower fixed portion 16a of the small convex lens 6 and the shade 4 are integrally formed, the relative positions of the small convex lens 6, the small concave mirror 7, the LED 11, and the shade 4 that are optically important in positional relationship are determined. Therefore, the small projector type lamp 10 which is optically excellent can be formed with a stable quality.

  Further, since the small projector lamp 10 has a small number of parts, the parts can be easily managed, can be easily assembled, and the cost can be reduced.

  Next, a modified example of the small projector type lamp 10 will be shown.

  The first modification is characterized in that the first resin material used for forming the small reflector 14 and the second resin material used for forming the small convex lens 6 are the same resin material. For example, the small convex lens 6 and the small reflector 14 are formed using the same transparent resin material made of polycarbonate resin, acrylic resin, or the like.

  In this configuration, the small convex lens 6 and the small reflector 14 are formed with the same physical properties such as a coefficient of thermal expansion, so that the occurrence of distortion due to thermal deformation can be avoided as much as possible. Ten optically superior properties can be maintained over a long period of use.

  Further, in the second modification, the first resin material used for forming the small reflector 14 is a transparent resin material such as polycarbonate resin and acrylic resin, and aluminum deposition is performed on the inner surfaces of the upper and lower reflectors 12 and 13. Configured.

  In this structure, since the upper and lower reflectors 12 and 13 constituting the small reflector 14 are formed of a transparent resin material, the aluminum vapor deposition layer on the inner surface is visually recognized from the outside as if it had a metal decoration on the outer side. Can improve the appearance.

It is a front view of the whole projector type vehicle lamp as an embodiment of the present invention. It is sectional drawing which follows the II-II line | wire of the projector type vehicle lamp of FIG. It is sectional drawing which follows the III-III line | wire of the projector type vehicle lamp of FIG. It is a disassembled side view of the small projector type lamp applied to the projector type vehicle lamp of FIG. FIG. 5 is a perspective view of an LED sub-assembly applied to a light source of the small projector type lamp of FIG. 4. 1 is a light distribution pattern of each of a plurality of small projector type lamps constituting the projector type vehicle lamp of FIG. 1, (a) is a horizontal diffusion type, (b) is a condensing flat type, and (c) is a cut line. The horizontal beam diffusion type for the passing beam has (d) shows the converging flat type for the passing beam having a cut line. FIG. 2 is a small projector type lamp as an embodiment constituting the projector type vehicle lamp of the present invention, wherein (a) is a plan view thereof, (b) is a sectional view taken along line VIIb-VIIb of (a), and (c). FIG. 3 is a front view seen from the front. It is a graph which shows the emission pattern of the emitted light of LED applied to the small projector type lamp of FIG. It is a graph which shows the light distribution pattern of the projector type vehicle lamp comprised with the small projector type lamp of FIG. 7 is a small reflector applied to the small projector type lamp of FIG. 7, (a) is a rear view of the upper reflector, (b) is a rear view of the lower reflector, and (c) is a cross section taken along line Xc-Xc of (a). FIG. It is a center secondary sectional view of the conventional projector type vehicle lamp. It is a front view of the concave mirror applied to the projector type vehicle lamp of FIG.

Explanation of symbols

4 Shade 6 Small convex lens 7 Small concave mirror 10 Small projector type lamp 10a to 10j Small projector type lamp 11 LED
11a Light emitting part (LED)
12 Upper reflector 13 Lower reflector 14 Small reflector 14a Lamp room (front lamp room)
15a Upper fixed part 16a Lower fixed part 19 Light source fixed part 20 Housing A Projector type vehicle lamp F1 First focus (of a small concave mirror)

Claims (2)

A projector-type vehicle comprising: a light source provided in the vicinity of a first focal point of a concave mirror; and a convex lens for dimming a light beam emitted from the light source and reflected by the concave mirror into a substantially parallel light beam and emitting the light in front of the lamp A lamp,
The light source has one light emitting portion facing the small concave mirror in the vicinity of the first focal point of the small concave mirror formed on each of a plurality of small reflectors as a free-form surface based on a spheroidal curved surface or a rotational ellipse. It consists of multiple LEDs that are set one by one,
The small reflector and the small convex lens that covers the opening of the small reflector are formed of the same transparent resin material with the same coefficient of thermal expansion ,
The small reflector includes an upper reflector formed integrally with the upper fixed portion of the small convex lens, the small concave mirror, and a light source fixed portion, and a lower fixed portion of the small convex lens and a shade formed integrally with the upper reflector. A lower reflector coupled from the lower side,
The upper reflector and the lower reflector are coupled to each other, the small convex lens is fixed by the upper fixing portion and the lower fixing portion, and the LED is fixed to the light source fixing portion so as to be small for each small reflector. Construct a projector-type lamp
A projector-side vehicular lamp comprising a plurality of small projector-type lamps configured of the plurality of small reflectors incorporated in a single housing. The projector-type vehicle lamp according to claim 1 ,
The projector-type vehicular lamp, wherein the upper and lower reflectors constituting the small reflector are provided with aluminum vapor deposition on the inner surfaces thereof.

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