JP7518696B2 - Lighting unit - Google Patents

Description

The present invention relates to a lighting unit that is configured to irradiate light from a light source unit that is reflected by a rotating reflector toward the front of the unit via a projection lens.

Conventionally, there are known in-vehicle lighting units that are configured to irradiate light from a light source unit reflected by a spatial light modulator through a projection lens toward the front of the unit, as described in, for example, Patent Document 1, and that are configured to irradiate light from a light source unit reflected by a rotating reflector through a projection lens toward the front of the unit, as described in, for example, Patent Document 2.

The lamp unit described in Patent Document 1 is configured to be able to form a light distribution pattern for drawing (i.e., a light distribution pattern for drawing letters, symbols, etc.) on the road surface ahead of the vehicle by controlling the spatial distribution of reflected light in a spatial light modulator.

The lamp unit described in Patent Document 2 is configured to be able to form a light distribution pattern for drawing by controlling the light source unit to be turned on and off while the rotating reflector is rotated.

JP 2016-91976 A JP 2014-216049 A

If a configuration using a spatial light modulator like the lighting unit described in the above-mentioned "Patent Document 1" is used, it becomes possible to form a light distribution pattern for drawing with high accuracy, but it becomes an expensive configuration.

On the other hand, if a configuration is used that includes a rotating reflector like the lighting unit described in the above-mentioned "Patent Document 2," it is possible to form a light distribution pattern for drawing with a relatively inexpensive configuration, but since it is necessary to control the on/off of the light source unit, it is difficult to achieve further cost reduction.

The present invention was made in consideration of these circumstances, and aims to provide a lighting unit that is inexpensively constructed to form a light distribution pattern for drawing, in a lighting unit that is configured to irradiate light from a light source unit that is reflected by a rotating reflector toward the front of the unit via a projection lens.

The present invention aims to achieve the above objective by adopting a rotating reflector and improving its configuration.

That is, the lamp unit according to the present invention is
A lamp unit configured to irradiate light from a light source unit reflected by a rotating reflector toward the front of the unit through a projection lens,
The rotating reflector includes a reflector body having a plurality of reflecting surfaces and an actuator for rotating the reflector body,
the reflector body is configured such that, by driving the actuator, any one of the plurality of reflecting surfaces can be selectively disposed at a reflection control position at which the reflecting surface reflects the light from the light source unit toward the projection lens,
the light source unit is configured to emit light from a position on the front side of the unit that is offset from an optical axis of the projection lens with respect to the reflection control position;
the reflector body is formed such that an effective reflection area of the reflection surface arranged at the reflection control position is inclined toward the light source unit with respect to a plane perpendicular to the optical axis,
The effective reflection area is composed of a plurality of reflective elements arranged at intervals from each other, and the plurality of reflective elements are formed in a state inclined toward the light source unit on a plane perpendicular to the optical axis.

The light source unit may be configured to allow the light emitted from the light source to enter the rotating reflector as is, or may be configured to allow the light emitted from the light source to enter the rotating reflector after being controlled by a reflector, lens, etc.

The above-mentioned "rotating reflector" is configured so that any one of the multiple reflecting surfaces constituting the reflector body can be selectively positioned at a reflection control position by driving an actuator, and there are no particular limitations on the direction of the rotation axis or the specific shape of each reflecting surface.

The above-mentioned "effective reflection area" refers to an area that has the function of reflecting light from the light source unit toward the projection lens, and its specific shape is not particularly limited.

The lighting unit of the present invention is configured to irradiate light from the light source unit, reflected by a rotating reflector, toward the front of the unit via a projection lens. The rotating reflector is equipped with a reflector body with multiple reflective surfaces and an actuator that rotates it. By driving the actuator to selectively position one of the multiple reflective surfaces at a reflection control position, a light distribution pattern for drawing can be formed by the reflected light from the reflective surface positioned at the reflection control position.

In this case, the reflector body has at least two reflecting surfaces with different effective reflection area shapes as the multiple reflecting surfaces, so by rotating the reflector body by a predetermined angle, multiple types of drawing light distribution patterns can be formed according to the shapes of the effective reflection areas. Moreover, this can be achieved with an inexpensive configuration that only requires rotating the reflector body by a predetermined angle.

According to the present invention, a lighting unit configured to irradiate light from a light source unit reflected by a rotating reflector toward the front of the unit via a projection lens can form a light distribution pattern for drawing with an inexpensive configuration.

In the above configuration, if the effective reflection area is formed by performing a mirror finish on a portion of the reflection surface, a light distribution pattern for drawing with a clear outline can be formed.

In this case, the "partial area of the reflecting surface" may be an area for forming the light distribution pattern for drawing itself, or an area for forming the light distribution pattern for drawing in a hollowed-out shape.

If this configuration is adopted and the reflector body is made of a transparent material, the light from the light source unit that reaches the area that has not been mirror-finished can be made to enter the reflector body and be transmitted through it, thereby effectively preventing the reflector body from being inadvertently heated.

In the above configuration, if the light source unit is configured to cause light to be incident from a position on the front side of the unit that is offset from the optical axis of the projection lens relative to the reflection control position, and the reflector body is configured so that the effective reflection area of the reflection surface arranged at the reflection control position is inclined toward the light source unit with respect to a plane perpendicular to the optical axis of the projection lens, the reflected light from the effective reflection area can be efficiently incident on the projection lens.

In this case, if the effective reflection area is made up of a plurality of reflective elements arranged at intervals from each other, and the plurality of reflective elements are formed in a state inclined toward the light source unit on a plane perpendicular to the optical axis of the projection lens, the components of the light distribution pattern for drawing formed by the reflected light from each of the plurality of reflective elements can be formed with clear contours.

FIG. 1 is a perspective view showing a lamp unit according to a first embodiment of the present invention; FIG. 1 is a view taken in the direction of the arrow II. FIG. 1, viewed from the direction of arrow III IV arrow view of FIG. 3 is a cross-sectional view taken along line V-V of FIG. FIG. 2 is a perspective view showing the lamp unit as viewed obliquely from the rear. FIG. 2 is a perspective view showing the lamp unit disassembled into its main components. FIG. 4 is a perspective view showing a main part of a rotating reflector in the lamp unit; FIG. 13 is a diagram showing a light distribution pattern for drawing formed by light emitted from the lighting unit; FIG. 2 is a perspective view showing a light distribution pattern formed on a road surface ahead of a vehicle by light emitted from the lamp unit; FIG. 4 is a view similar to FIG. 3, showing a lamp unit according to a second embodiment of the present invention; FIG. 5 is a view similar to FIG. 4 showing the second embodiment. FIG. 6 is a view similar to FIG. 5 showing the second embodiment. FIG. 11 is a perspective view showing a lamp unit according to the second embodiment, partially exploded; 1A is a side cross-sectional view showing a main part of a rotating reflector in a lamp unit according to a modification of the second embodiment; FIG. 1B is a view taken in the direction of the arrow b in FIG. 1A; and FIG. 1C is a view showing a light distribution pattern for drawing formed by light emitted from the lamp unit according to the modification.

The following describes an embodiment of the present invention with reference to the drawings.

First, we will explain the first embodiment of the present invention.

Figure 1 is a perspective view showing the lamp unit 10 according to this embodiment. Also, Figure 2 is a view seen in the direction of the arrow II in Figure 1, Figure 3 is a view seen in the direction of the arrow III in Figure 1, Figure 4 is a view seen in the direction of the arrow IV in Figure 1, and Figure 5 is a cross-sectional view taken along line V-V in Figure 2. Furthermore, Figure 6 is a perspective view showing the lamp unit 10 as seen diagonally from behind, and Figure 7 is a perspective view showing the lamp unit 10 disassembled into its main components.

In these figures, the direction indicated by X is the "front of the unit," the direction indicated by Y is the "left direction" (the "right direction" when viewed from the front of the unit) that is perpendicular to the "front of the unit," and the direction indicated by Z is the "upward direction." This is the same for the other figures.

The lamp unit 10 according to this embodiment is configured as part of an in-vehicle road marking lamp (not shown). This road marking lamp is configured to form a light distribution pattern for marking on the road surface ahead of the vehicle by irradiating light from the lamp unit 10 when attached to the front end of the vehicle.

As shown in FIG. 5, the lamp unit 10 is configured to irradiate light from the light source unit 50, which is reflected by the rotating reflector 20, toward the front of the unit via the projection lens unit 70.

The rotating reflector 20, the light source unit 50, and the projection lens unit 70 are supported by a common bracket 40. This bracket 40 is a metal (e.g., aluminum die-cast) member and has a vertical surface portion 40A that extends along a vertical plane perpendicular to the front-to-rear direction of the unit, and a horizontal surface portion 40B that extends toward the front of the unit in the lower region of this vertical surface portion 40A.

The lamp unit 10 is configured to be supported by the lamp body (not shown) of the road marking lamp at its bracket 40 while being housed in the lamp chamber of the road marking lamp.

Note that in Figures 1 to 7, the lamp unit 10 is shown positioned so that its front-to-rear direction (i.e., the front-to-rear direction of the unit) extends horizontally, but when housed within the lamp chamber of the road marking lamp, the lamp unit 10 is positioned facing diagonally downward toward the front of the unit in order to form a light distribution pattern for marking on the road surface ahead of the vehicle.

As shown in Figures 4 to 6, the rotating reflector 20 is configured with a reflector body 22 having six reflecting surfaces 22a and an actuator 30 that rotates the reflector body 22.

The reflector body 22 is configured so that, by driving the actuator 30, any one of the six reflecting surfaces 22a can be selectively positioned at a reflection control position that reflects light from the light source unit 50 toward the projection lens unit 70.

As shown in Figures 1 to 3, the projection lens unit 70 includes a projection lens 72 having an optical axis Ax extending in the front-to-rear direction of the unit, and a lens holder 74 that supports the projection lens 72. The lens holder 74 is supported on the horizontal surface portion 40B of the bracket 40.

The light source unit 50 is positioned below the projection lens unit 70.

The light source unit 50 includes a pair of light sources (specifically, light-emitting diodes) 52 mounted on a substrate 56, and a reflector 54 that reflects the light emitted from each light source 52 toward the reflector body 22 of the rotating reflector 20.

As shown in FIG. 5, the bracket 40 is positioned so that the rear surface of the vertical surface portion 40A is located slightly forward of the rear focal point F of the projection lens 72. A horizontally elongated rectangular opening 40Aa is formed in the vertical surface portion 40A of the bracket 40 so as to surround the optical axis Ax. When viewed from the front of the unit, this opening 40Aa has an opening shape that is slightly larger than the reflection surface 22a positioned at the reflection control position, and is formed so as to expand in an inclined manner from the rear surface of the vertical surface portion 40A to the front surface around its entire circumference.

Next, the specific configuration of the rotating reflector 20 will be described.

Figure 8 is a perspective view showing the main parts of the rotating reflector 20.

As shown in FIG. 8, the reflector body 22 of the rotating reflector 20 is formed in a hexagonal prism shape and is fixedly supported by the shaft 24.

As shown in FIG. 6, the shaft 24 is disposed on an axis Ax1 that extends horizontally and perpendicular to the optical axis Ax, and is supported rotatably with respect to the vertical surface portion 40A of the bracket 40 at two locations on both the left and right sides of the reflector body 22.

Specifically, the shaft 24 is supported by a pair of left and right shaft support parts 40Ab formed to protrude toward the rear side of the unit from the rear surface of the vertical surface part 40A of the bracket 40, and a pair of left and right fasteners 26 fixed to these by screw tightening or the like, in a state in which the shaft 24 is sandwiched on both sides in the front-rear direction of the unit, and is capable of rotating around the axis Ax1 in this state.

A pair of annular protrusions 24a are formed on the left and right sides of the reflector body 22 of the shaft 24, and these engage with a pair of shaft supports 40Ab and fasteners 26, thereby positioning the shaft 24 in the direction in which the axis Ax1 extends.

A pin gear 28 is fixedly supported at the right end of the shaft 24.

The actuator 30 is fixed to the bracket 40 at the right end of the bracket 40 via the actuator holder 32.

The actuator 30 is composed of a stepping motor with an output shaft that protrudes toward the rear of the unit, and a spur gear 34 is fixed to the output shaft.

The actuator 30 is positioned so that its spur gear 34 engages with the pin gear 28 of the shaft 24 while protruding toward the rear of the unit through an opening 40Ac formed in the vertical surface portion 40A of the bracket 40.

The actuator 30 is configured to be driven and controlled according to the vehicle driving conditions, and is capable of rotating the reflector body 22 by a predetermined angle around the axis Ax1.

The reflector body 22 is made of a colored resin (e.g., black polycarbonate resin), and the outer periphery of the hexagonal prism is configured as six reflective surfaces 22a.

The reflector body 22 is designed so that, by driving the actuator 30, any one of the six reflecting surfaces 22a can be selectively positioned at a reflection control position where the light from the light source unit 50 is reflected toward the projection lens 72.

As shown in FIG. 5, the actuator 30 is configured to rotate the reflector body 22 so that the reflecting surface 22a, which is positioned at the reflection control position, is inclined toward the front of the unit by a predetermined angle θ (e.g., θ=12° or so) with respect to a vertical plane perpendicular to the optical axis Ax at the rear focal point F of the projection lens 72.

In each of the six reflecting surfaces 22a, the areas that have the function of reflecting light from the light source unit 50 toward the projection lens 72 are formed as effective reflecting areas 22a1, 22a2, 22a3, 22a4, 22a5, and 22a6, each of which has a different outer shape.

Specifically, as shown in FIG. 8, when the reflecting surface 22a is placed in the reflection control position, the effective reflection area 22a1 is formed as a downward arrow, the effective reflection area 22a2 is formed as two arrows arranged in series facing downward, the effective reflection area 22a3 is formed as a rightward arrow, the effective reflection area 22a4 is formed as a leftward arrow, the effective reflection area 22a5 is formed as three band-shaped areas arranged in horizontal stripes spaced apart in the vertical direction, and the effective reflection area 22a6 is formed as four band-shaped areas arranged in vertical stripes spaced apart in the horizontal direction.

Each effective reflection area 22a1 to 22a6 is formed by performing a mirror finish such as aluminum deposition on a portion of each reflection surface 22a.

Next, the specific configuration of the light source unit 50 will be described.

Each light source 52 is composed of a light-emitting diode that emits green light and is supported by the light source holder 60 via a substrate 56.

The board 56 is equipped with connectors 58 for supplying power to the pair of light sources 52 on the left and right.

The light source holder 60 is configured as a heat sink equipped with a cooling fan 62 and is fixedly supported on the horizontal surface portion 40B of the bracket 40.

The reflector 54 has a pair of reflecting surfaces 54a on the left and right, and is configured to converge the light emitted from each light source 52 at the rear focal point F of the projection lens 72 (see Figure 5) on each reflecting surface 54a.

In addition, an opening 40Bb is formed in the horizontal surface portion 40B of the bracket 40 for inserting the reflector 54 through.

Next, the specific configuration of the projection lens unit 70 will be described.

As shown in FIG. 5, the projection lens 72 is composed of first, second and third lenses 72A, 72B and 72C arranged side by side in the front-to-rear direction of the unit on the optical axis Ax.

The first lens 72A, located closest to the front of the lamp, is configured as a substantially plano-convex lens that bulges toward the front of the lamp, the second lens 72B, located in the center, is configured as a biconcave lens, and the third lens 72C, located closest to the rear of the lamp, is configured as a biconvex lens.

The first to third lenses 72A to 72C are all made of resin lenses. Specifically, the first and third lenses 72A and 72C are made of acrylic resin, and the second lens 72B is made of polycarbonate resin.

The first to third lenses 72A to 72C have their upper ends slightly cut away along the horizontal plane and their lower ends cut away relatively largely along the horizontal plane. The first to third lenses 72A to 72C are supported at their outer peripheries by a common lens holder 74 via mounting brackets 76A and 76B.

The lens holder 74 is a metal member (e.g., aluminum die-cast) and includes a holder body 74A formed to cylindrically surround the projection lens 72, and holder legs 74B formed to protrude on both the left and right sides from the lower end of the outer circumferential surface of the holder body 74A.

A first metal fitting 76A is attached to the holder body 74A from the front side of the lamp, and a second metal fitting 76B is attached to the rear side of the lamp, thereby fixing the first to third lenses 72A to 72C to the holder body 74A.

The holder legs 74B are placed on the horizontal surface 40B of the bracket 40 at both left and right ends. At this time, a pair of left and right engagement grooves 40Ba are formed on the horizontal surface 40B of the bracket 40, which engage with a pair of left and right protrusions 74Ba formed on the underside of both left and right ends of the holder legs 74B. The projection lens unit 70 is configured so that it can be fixed to the bracket 40 by the lens holder 74 when the projection lens 72 is focused by adjusting the position of the lens holder 74 in the front-to-rear direction of the unit.

Figure 9 shows a light distribution pattern for drawing formed on a virtual vertical screen placed in front of the vehicle by the light emitted from the lamp unit 10 according to this embodiment.

The drawing light distribution patterns P1 to P6 shown in Figures 9(a) to (f) are light distribution patterns formed when the reflecting surface 22a, on which each of the effective reflection areas 22a1 to 22a6 is formed, of the reflector body 22 of the rotating reflector 20 is positioned in the reflection control position.

The light distribution pattern for drawing P1 shown in FIG. 9(a) is a light distribution pattern in the shape of an upward arrow as an inverted projection image, since the effective reflection area 22a1 is formed as a downward arrow.

The drawing light distribution pattern P2 shown in FIG. 9(b) is formed as two arrows arranged in series facing downward in the effective reflection area 22a2, and its inverted projection image is a light distribution pattern in the shape of two arrows arranged in series facing upward.

The light distribution pattern for drawing P3 shown in FIG. 9(c) is a light distribution pattern in the shape of a left-pointing arrow as an inverted projection image, since the effective reflection area 22a3 is formed as a right-pointing arrow.

The light distribution pattern for drawing P4 shown in FIG. 9(d) is a light distribution pattern in the shape of a right-pointing arrow as an inverted projection image, since the effective reflection area 22a4 is formed as a left-pointing arrow.

The drawing light distribution pattern P5 shown in FIG. 9(e) is formed as three stripe-shaped regions arranged in horizontal stripes with vertical spacing between them in the effective reflection area 22a5, and as an inverted projection image, it is a light distribution pattern consisting of three stripe-shaped regions arranged in horizontal stripes with vertical spacing between them.

The drawing light distribution pattern P6 shown in FIG. 9(f) is formed as four stripe-shaped regions arranged in vertical stripes with intervals in the left-right direction in the effective reflection area 22a6, and therefore the inverted projection image is a light distribution pattern consisting of four stripe-shaped regions arranged in vertical stripes with intervals in the left-right direction.

Note that the area Z indicated by the two-dot dashed line in Figures 9(a) to (f) indicates the range in which the light distribution pattern for drawing can be formed (i.e., the range in which the light distribution pattern for drawing can be formed if the entire area of the reflecting surface 22a were the effective reflecting area).

Figure 10 is a perspective view of the light distribution pattern P1 for drawing that is formed when the reflecting surface 22a, on which the effective reflecting area 22a1 is formed, is positioned in the reflecting control position.

As shown in FIG. 10, the drawing light distribution pattern P1 is formed together with (or independently of) the low beam light distribution pattern PL formed by the light emitted from another lamp unit (not shown).

The low beam light distribution pattern PL is a low beam light distribution pattern for left light distribution, and has cutoff lines CL1 and CL2 at its upper edge.

The cutoff lines CL1 and CL2 are formed as follows: the portion of the cutoff line CL1 on the oncoming lane side to the right of the V-V line that passes vertically through H-V, which is the vanishing point in front of the lamp, is formed as a horizontal cutoff line CL1, and the portion of the own lane side to the left of the V-V line is formed as a diagonal cutoff line CL2, with the elbow point E, where the two intersect, being located approximately 0.5 to 0.6° below H-V.

On the other hand, the drawing light distribution pattern P1 is formed on the road surface in front of the vehicle as an arrow-shaped light distribution pattern facing in the forward direction of the vehicle, thereby calling attention to the surroundings.

In this case, since the light source 52 of the light source unit 50 is composed of a light-emitting diode that emits green light, the drawing light distribution pattern P1 is also formed as a green light distribution pattern.

When the vehicle is traveling at night, this arrow-shaped light distribution pattern P1 is formed to alert those around the vehicle that it is approaching an intersection ahead of the vehicle, for example, to draw attention to the situation.

Next, the operation of this embodiment will be explained.

The lighting unit 10 according to this embodiment is configured to irradiate light from the light source unit 50 reflected by the rotating reflector 20 toward the front of the unit via the projection lens 72. The rotating reflector 20 is equipped with a reflector body 22 having six reflecting surfaces 22a and an actuator 30 that rotates it. By driving the actuator 30 to selectively position one of the six reflecting surfaces 22a at the reflection control position, a light distribution pattern for drawing can be formed by the reflected light from the reflecting surface 22a positioned at the reflection control position.

In this case, since the shapes of the effective reflection areas 22a1 to 22a6 of the six reflection surfaces 22a of the reflector body 22 are different from one another, by rotating the reflector body 22 by 60° each, six types of drawing light distribution patterns P1 to P6 corresponding to the shapes of the effective reflection areas 22a1 to 22a6 can be formed. Moreover, this can be achieved with an inexpensive configuration that only requires rotating the reflector body 22 by 60° each.

According to this embodiment, the lighting unit 10 is configured to irradiate the light from the light source unit 50 reflected by the rotating reflector 20 toward the front of the unit via the projection lens 72, making it possible to form the light distribution patterns P1 to P6 for drawing with an inexpensive configuration.

In particular, in this embodiment, the effective reflection areas 22a1 to 22a6 are formed by performing a mirror finish on a portion of the reflection surface 22a, so that drawing light distribution patterns P1 to P6 with clear contours can be formed.

In this embodiment, the light source unit 50 is configured to cause light to enter from a diagonally downward position on the unit's front side relative to the reflection control position (i.e., a position on the unit's front side that is off the optical axis Ax of the projection lens 72). However, the rotating reflector 20 is configured such that the effective reflection areas 22a1-22a6 of the reflection surface 22a arranged at the reflection control position are arranged in a state in which they are tilted forward by a predetermined angle θ with respect to a vertical plane perpendicular to the optical axis Ax of the projection lens 72 (i.e., in a state in which they are tilted by a predetermined angle θ toward the light source unit 50), so that the reflected light from the effective reflection areas 22a1-22a6 can be efficiently incident on the projection lens 72.

In the first embodiment, the reflector body 22 is described as being made of a colored resin material, but it can also be made of a transparent resin material (e.g., colorless and transparent polycarbonate resin). When such a configuration is adopted, light from the light source unit 50 that reaches the area of the six reflecting surfaces 22a that is not mirror-finished (i.e., the area surrounding the effective reflecting areas 22a1 to 22a6) can be made to enter the reflector body 22 and transmitted. Therefore, it is possible to effectively prevent the reflector body 22 from being accidentally heated, and thereby to prevent problems such as melting from occurring. It is also possible to make the reflector body 22 out of a metal material (e.g., aluminum die-cast).

In the above first embodiment, the effective reflection areas 22a1 to 22a6 are described as being formed by mirror finishing the area near the center of the reflection surface 22a, but it is also possible to configure them to be formed by mirror finishing the area surrounding the area near the center. In this case, the drawing light distribution patterns P1 to P6 are formed as light distribution patterns with a hollow shape.

In the first embodiment, the reflector body 22 is described as having six reflecting surfaces 22a, but it is also possible to configure it with five or fewer reflecting surfaces 22a or seven or more reflecting surfaces 22a.

In the first embodiment, the light source 52 is described as being configured as a light-emitting diode that emits green light, but the light source 52 can also be configured to emit light of a color other than green, such as blue or white.

In the above first embodiment, the optical axis Ax of the projection lens 72 and the axis Ax1 of the reflector body 22 of the rotating reflector 20 are described as being at the same height, but it is also possible to configure the axis Ax1 to be displaced upward with respect to the optical axis Ax. By adopting such a configuration, it is also possible to form a light distribution pattern for drawing on the road surface in front of the vehicle while maintaining the state in which the lamp unit 10 is arranged horizontally.

In the first embodiment, the lamp unit 10 is described as an in-vehicle lamp unit, but it can also be used for purposes other than in-vehicle use (for example, a street lamp unit configured to draw on the road surface from diagonally above, etc.).

Next, we will explain the second embodiment of the present invention.

Figures 11, 12, and 13 are similar to Figures 3, 4, and 5, but show a lamp unit 110 according to a second embodiment of the present invention, and Figure 14 is a perspective view showing the lamp unit 110, partly exploded.

As shown in Figures 11 to 14, the basic configuration of this embodiment is similar to that of the first embodiment, but the configuration of the rotating reflector 120 is partially different from that of the first embodiment, and therefore the configuration of the bracket 140 is also partially different from that of the first embodiment.

That is, the lamp unit 110 according to this embodiment is also configured to irradiate the light from the light source unit 50 reflected by the rotating reflector 120 toward the front of the unit via the projection lens unit 70, and these are supported by a common bracket 140.

The bracket 140 of this embodiment is also a metal member, and has a vertical surface portion 140A that extends along a vertical plane perpendicular to the front-to-rear direction of the unit, and a horizontal surface portion 140B that extends toward the front of the unit in the lower region of this vertical surface portion 140A, and is positioned so that the rear surface of the vertical surface portion 140A is located slightly forward of the rear focal point F of the projection lens 72.

As in the first embodiment, a horizontally elongated rectangular opening 140Aa is formed in the vertical surface portion 140A of the bracket 140 so as to surround the optical axis Ax, and an opening 140Bb is formed in the horizontal surface portion 140B of the bracket 140 for inserting the reflector 54.

The rotating reflector 120 of this embodiment is configured with a reflector body 122 having six reflecting surfaces 122a, a reflector holder 124 that supports the reflector body 122, and an actuator 30 similar to that of the first embodiment that rotates the reflector holder 124.

The reflector body 122 is configured so that, by driving the actuator 30, any one of the six reflecting surfaces 122a can be selectively positioned at a reflection control position that reflects light from the light source unit 50 toward the projection lens unit 70.

The reflector body 122 is a member made of transparent resin, and is configured with six protrusions 122B formed on the front surface of a disk-shaped base portion 122A that extends along a vertical plane perpendicular to the optical axis Ax.

The reflector body 122 is configured to rotate around an axis Ax2 that extends parallel to the optical axis Ax at a position away from the optical axis Ax to the right.

A circular opening 122b is formed at the center of the disk-shaped base portion 122A at the position of the axis Ax2. Six protrusions 122B are formed at 60° intervals in the circumferential direction around the axis Ax2. Each protrusion 122B has a rectangular outer shape that is elongated and extends radially when viewed from the front of the lamp, and its front surface is configured as a reflective surface 122a.

Each reflecting surface 122a is formed of a plane inclined in the circumferential direction with respect to the axis Ax2. Specifically, each reflecting surface 122a is formed in a state inclined at a predetermined angle θ (e.g., θ = approximately 12°) toward the rear of the unit in a clockwise direction when the lamp is viewed from the front.

In each of the six reflecting surfaces 122a, the areas that have the function of reflecting light from the light source unit 50 toward the projection lens 72 are formed as effective reflecting areas 122a1, 122a2, 122a3, 122a4, 122a5, and 122a6, each of which has a different outer shape.

Specifically, as shown in FIG. 14, when the reflecting surface 122a is placed in the reflection control position, the effective reflection area 122a1 is formed as a downward arrow, the effective reflection area 122a2 is formed as two arrows arranged in series facing downward, the effective reflection area 122a3 is formed as a rightward arrow, the effective reflection area 122a4 is formed as a leftward arrow, the effective reflection area 122a5 is formed as three band-shaped areas arranged in horizontal stripes spaced apart in the vertical direction, and the effective reflection area 122a6 is formed as six band-shaped areas arranged in vertical stripes spaced apart in the horizontal direction. However, in this embodiment, the order of the six effective reflection areas 122a1 to 122a6 is different from that in the first embodiment.

Each effective reflection area 122a1 to 122a6 is formed by performing a mirror finish such as aluminum deposition on a portion of each reflection surface 122a.

On the front surface of the disk-shaped base portion 122A, three positioning pins 122c are formed at 120° intervals around the axis Ax2, extending toward the front of the unit.

The reflector holder 124 is configured as a disc-shaped member made of colored resin (e.g., polyacetal resin) with an outer diameter larger than the disc-shaped base portion 122A of the reflector body 122.

A circular opening 124a is formed in the center of the reflector holder 124, and the annular region surrounding this is formed as a thick portion 124b. Six openings 124c are formed around the thick portion 124b in the reflector holder 124 at intervals of 60° in the circumferential direction. In addition, three pin insertion holes 124d are formed in the reflector holder 124 at intervals of 120° in the circumferential direction.

Spur teeth 124e are formed all around the outer periphery of the reflector holder 124, which configures the reflector holder 124 as a large-diameter external gear.

The rotating reflector 120 is rotatably supported on the vertical surface 140A of the bracket 140 by a shaft 126 arranged on the axis Ax2, with the reflector body 122 attached to the reflector holder 124 from the rear side of the unit.

At this time, the three positioning pins 122c of the reflector body 122 are inserted into the three pin insertion holes 124d of the reflector holder 124, and further, the six protrusions 122B of the reflector body 122 are inserted into the six openings 124c of the reflector holder 124, and the shaft 126 is inserted from the rear side of the unit into the circular opening 122b of the reflector body 122 and the circular opening 124a of the reflector holder 124. At this time, the spur teeth 124e formed on the outer circumferential surface of the reflector holder 124 mesh with the spur gear 34 of the actuator 30.

The shaft 126 is fixed at its front end to the vertical surface 140A of the bracket 140 by press-fitting or the like, and an E-ring 128 is attached to its rear end to prevent the reflector body 122 and reflector holder 124 from coming loose.

Next, the operation of this embodiment will be explained.

The lamp unit 110 according to this embodiment is configured to irradiate the light from the light source unit 50 reflected by the rotating reflector 120 toward the front of the unit through the projection lens 72. The rotating reflector 120 is equipped with a reflector body 122 having six reflecting surfaces 122a and an actuator 30 that rotates it. By selectively positioning one of the six reflecting surfaces 122a at the reflection control position by driving the actuator 30, six types of light distribution patterns for drawing can be formed by the light reflected from the effective reflection areas 122a1 to 122a6 of the reflecting surface 122a positioned at the reflection control position, as in the first embodiment. Moreover, this can be achieved by an inexpensive configuration that only requires rotating the reflector body 122 by 60°.

In particular, in this embodiment, the reflector body 122 is made of a transparent material, so that light from the light source unit 50 that reaches the areas of the six reflecting surfaces 122a that are not mirror-finished (i.e., the areas surrounding the effective reflecting areas 122a1-122a6) can be made to enter the reflector body 122 and transmitted therethrough, thereby effectively preventing the reflector body 122 from being inadvertently heated.

In addition, in this embodiment, the reflector body 122 is supported by the reflector holder 124, so the structure of the reflector body 122 itself can be simplified. Moreover, the reflector body 122 is covered from the front side of the unit by the reflector holder 124 except for the six protrusions 122B, so stray light can be prevented from occurring when light from the light source unit 50 enters the disk-shaped base portion 122A.

Next, we will explain a variation of the second embodiment.

Figure 15(a) is a view similar to part of Figure 13, showing the main part of the rotating reflector 120 in the lamp unit according to this modified example, and Figure 15(b) is a view seen in the direction of the arrow b in Figure 15(a).

The basic configuration of this modified example is the same as that of the second embodiment described above, but the configuration of the reflector body 222 is partially different from that of the second embodiment described above.

In other words, the reflector body 222 of this modified example is also a member made of transparent resin, and is configured such that six protrusions 222B are formed on the front surface of a disk-shaped base portion (not shown) that extends along a vertical plane perpendicular to the optical axis Ax, and the front surface is configured as the reflective surface 222a.

In this modified example, the effective reflection area 222a7 having a reflection function on the reflection surface 222a arranged at the reflection control position is composed of a plurality of reflection elements 222a7s arranged at equal intervals in the vertical and horizontal directions. Specifically, the effective reflection area 222a7 is configured such that square reflection elements 222a7s are arranged at five locations in the horizontal direction and three locations in the vertical direction centered on the optical axis Ax.

In this case, each of the multiple reflecting elements 222a7s is formed as an inclined surface inclined forward at a predetermined angle θ (for example, θ = approximately 12°) with respect to the same vertical plane including the rear focal point F of the projection lens 72.

Figure 15 (c) shows a drawing light distribution pattern P7 formed on a virtual vertical screen placed in front of the vehicle by the light emitted from the lamp unit of this modified example.

This drawing light distribution pattern P7 is composed of multiple reflective elements 222a7s arranged at equal intervals in the vertical and horizontal directions in the effective reflective area 222a7, and as an inverted projection image, multiple light distribution pattern components P7s are formed with a square external shape at equal intervals in the vertical and horizontal directions.

On the other hand, the drawing light distribution pattern P7' shown by the two-dot chain line in Figure 15 (c) is a light distribution pattern formed when, as shown by the two-dot chain line in Figure 15 (a), the effective reflection area 222a7' on the reflection surface 222a' arranged at the reflection control position is composed of multiple reflection elements 222a7s' formed on the same inclined surface inclined forward by a predetermined angle θ with respect to the vertical plane including the rear focus F of the projection lens 72.

This drawing light distribution pattern P7' also has an effective reflection area 222a7' that is composed of multiple reflection elements 222a7s' that are equally spaced in the vertical and horizontal directions, so that its inverted projection image has multiple light distribution pattern components P7s' that have a square outer shape and are equally spaced in the vertical and horizontal directions, but the light distribution pattern components P7s' located in the upper and lower rows have blurred square contours.

This is because, of the multiple reflective elements 222a7s' that make up the effective reflective area 222a7', the reflective elements 222a7s' located in the upper and lower rows are displaced in the front-to-rear direction of the unit from the vertical plane that includes the rear focal point F of the projection lens 72.

In contrast, in this modified example, on the reflecting surface 222a arranged at the reflection control position, each of the multiple reflecting elements 222a7s is formed as an inclined surface inclined forward by a predetermined angle θ with respect to the same vertical plane including the rear focal point F of the projection lens 72, so that the multiple light distribution pattern components P7s that make up the drawing light distribution pattern P7 are all formed without blurring the outline of a square.

By adopting the configuration of this modified example in this manner, the multiple light distribution pattern components P7s formed by the reflected light from each of the multiple reflecting elements 222a7s can be formed with clear contours, and this allows the drawing light distribution pattern P7 as a whole to be formed with clear contours.

The configuration of this modified example can also be applied to the lamp unit 10 according to the first embodiment.

Note that the numerical values shown as the specifications in each of the above embodiments and their modified examples are merely examples, and it goes without saying that these may be set to different values as appropriate.

Furthermore, the present invention is not limited to the configurations described in the above embodiments and their modified examples, and various other modified configurations may be adopted.

10 Lamp unit 20 Rotating reflector 22 Reflector body 22a Reflecting surface 22a1, 22a2, 22a3, 22a4, 22a5, 22a6 Effective reflecting area 24 Shaft 24a Annular protrusion 26 Fixing device 28 Pin gear 30 Actuator 32 Actuator holder 34 Spur gear 40 Bracket 40A Vertical surface 40Aa, 40Ac, 40Bb Opening 40Ab Shaft support 40B Horizontal surface 40Ba Engagement groove 50 Light source unit 52 Light source 54 Reflector 54a Reflecting surface 56 Board 58 Connector 60 Light source holder 62 Cooling fan 70 Projection lens unit 72 Projection lens 72A First lens 72B Second lens 72C Third lens 74 Lens holder 74A Holder body 74B Holder leg 74Ba Projection 76A, 76B Mounting bracket 110 Lamp unit 120 Rotating reflector 122, 222 Reflector body 122A Disk-shaped base 122a, 222a Reflecting surface 122a1, 122a2, 122a3, 122a4, 122a5, 122a6, 222a7 Effective reflection area 122B, 222B Projection 122b, 124a Circular opening 122c Positioning pin 124 Reflector holder 124b Thick portion 124c, 140Aa, 140Bb Opening 124d Pin insertion hole 124e Spur tooth 126 Shaft 128 E-ring 140 Bracket 140A Vertical surface portion 140B Horizontal surface portion 222a7s Reflection element Ax Optical axis Ax1, Ax2 Axis CL1 Horizontal cutoff line CL2 Oblique cutoff line E Elbow point F Rear focal point PL Light distribution pattern for low beam P1, P2, P3, P4, P5, P6, P7 Light distribution pattern for drawing P7s Light distribution pattern component Z Area θ Predetermined angle

Claims (3)

A lamp unit configured to irradiate light from a light source unit reflected by a rotating reflector toward the front of the unit through a projection lens,
The rotating reflector includes a reflector body having a plurality of reflecting surfaces and an actuator for rotating the reflector body,
the reflector body is configured such that, by driving the actuator, any one of the plurality of reflecting surfaces can be selectively disposed at a reflection control position at which the reflecting surface reflects the light from the light source unit toward the projection lens,
the light source unit is configured to emit light from a position on the front side of the unit that is offset from an optical axis of the projection lens with respect to the reflection control position;
the reflector body is formed such that an effective reflection area of the reflection surface arranged at the reflection control position is inclined toward the light source unit with respect to a plane perpendicular to the optical axis,
The effective reflection area is composed of a plurality of reflection elements arranged at intervals from each other, and the plurality of reflection elements are formed in a state inclined toward the light source unit on a plane perpendicular to the optical axis. The lamp unit according to claim 1, characterized in that the effective reflection area is formed by performing a mirror finish on a portion of the reflection surface. The lamp unit according to claim 2, characterized in that the reflector body is made of a transparent material.

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