CN212617736U

CN212617736U - Lamp unit

Info

Publication number: CN212617736U
Application number: CN202020606536.9U
Authority: CN
Inventors: 野村幸生
Original assignee: Koito Manufacturing Co Ltd
Current assignee: Koito Manufacturing Co Ltd
Priority date: 2019-05-07
Filing date: 2020-04-21
Publication date: 2021-02-26
Anticipated expiration: 2030-04-21
Also published as: JP7411134B2; JP2020184445A; JP2023090997A; JP7280104B2

Abstract

The utility model relates to a lamp unit. The problem is to reduce the number of parts and to miniaturize a projection-type lamp unit provided with a reflector. The lamp unit includes a heat sink 22 for supporting the light emitting element 14, and a lens holder 24 for supporting the projection lens 12, the reflector 16 is fixed to the lens holder 24 by caulking at both right and left portions thereof, and the heat sink 22 is fixed to the lens holder 24 by caulking at both right and left portions thereof. Thus, the number of parts of the lamp unit (10) is reduced.

Description

Lamp unit

Technical Field

The utility model relates to a projection type's lamps and lanterns unit with reflector.

Background

Conventionally, a projection-type lamp unit configured to cause light emitted from a light-emitting element reflected by a reflector to enter a projection lens is known. As a configuration of such a lamp unit, a lamp unit provided with a heat sink supporting a light emitting element and a lens holder supporting a projection lens is also known.

Patent document 1 describes a configuration of such a lamp unit in which a reflector is fixed to a lens holder by caulking at both right and left positions of the reflector, and the lens holder is fastened to a heat sink by screws at both right and left positions of the lens holder.

[ patent document 1 ] Japanese patent laid-open No. 2012 and 64494

In the conventional lamp unit described above, the reflector is fixed to the lens holder by caulking at two locations on the left and right of the reflector, and therefore the number of parts can be reduced as compared with the case where the reflector is fixed by screwing or the like. However, it is desired to reduce the number of parts in addition to reducing the cost of the lamp unit.

In the conventional lamp unit described above, the lens holder is screwed to the heat sink at two positions on the right and left sides of the lens holder, and therefore, a relatively large working space for moving a tool for screwing needs to be secured, and thus, it is not easy to downsize the lamp unit.

SUMMERY OF THE UTILITY MODEL

The present invention has been made in view of such circumstances, and an object of the present invention is to provide a projection type lamp unit provided with a reflector, in which the number of parts can be reduced and the size can be reduced.

The utility model discloses a fixed knot to reflector, radiator and lens holder between each other constructs to carry out the research improvement to realize above-mentioned purpose.

That is, the present invention provides a lamp unit including a projection lens, a light emitting element disposed on a unit rear side of the projection lens, and a reflector for reflecting light emitted from the light emitting element toward the projection lens, the lamp unit characterized in that:

a lens holder including a heat sink supporting the light emitting element and supporting the projection lens;

the reflector is riveted and fixed on the lens frame at the left part and the right part of the reflector;

the radiator is riveted and fixed on the lens frame at the left and right positions of the radiator.

The "rivet fixing of the reflector" is not particularly limited in kind and specific position if it is performed at two positions on the right and left of the reflector. The "caulking and fixing of the reflector" may be performed by deforming the reflector or deforming the lens holder.

The type and specific position of the "caulking of the heat sink" are not particularly limited if the caulking is performed at two locations on the right and left of the heat sink. The "caulking and fixing of the heat sink" may be performed by deforming the heat sink or by deforming the lens holder.

The effects of the present invention are explained below:

the utility model relates to a lamp unit constitutes as making the light that jets out that comes from light emitting element by the reflector reflection incides the lamp unit of projection lens, constitutes for including the radiator that supports light emitting element and the lens holder that supports projection lens, and the reflector is at its left and right sides two riveting fixed in the lens holder, and the radiator is also at its left and right sides two riveting fixed in the lens holder, consequently, can reduce lamp unit's part quantity to can reduce lamp unit's cost.

Further, since the work space required for the caulking fixation is smaller than the work space required for the screw tightening fixation, the size of the lamp unit can be reduced as compared with a conventional lamp unit in which the lens holder and the heat sink are fixed by screws.

Further, since the caulking fixation occupies a smaller space than the screw fixation, the size of the lamp unit can be reduced in this respect.

Thus, according to the present embodiment, in the projection type lamp unit provided with the reflector, the number of parts can be reduced and the size can be reduced.

In the above configuration, if the reflector and the radiator are fixed to the lens holder from both the upper and lower sides, a working space for performing the respective caulking can be easily secured, and the lamp unit can be further downsized.

In the above configuration, if the lens holder is made of a resin member and both the caulking fixation of the reflector and the caulking fixation of the heat sink are performed by thermal caulking, the work efficiency of the caulking fixation can be improved.

In the above configuration, if the caulking of the reflector is performed on the unit rear side of the heat sink, the reflector can be positioned with high accuracy, and the optical characteristics of the lamp unit can be improved.

In the above configuration, if the heat sink is configured as a heat sink, and the abutting portion abutting against the lens holder is provided at a portion of the heat sink located on the unit front side of the caulking-fixing position, the lens holder of the heat sink can be supported by the three-point support structure, and the positioning accuracy of the projection lens can be improved. Therefore, the positional relationship accuracy between the light emitting element supported by the heat sink, the reflector supported by the lens holder, and the projection lens can be improved, and the optical characteristics of the lamp unit can be improved.

In the above configuration, further, a movable shade configured to be positionable between a light shielding position for shielding a part of reflected light from the reflector and a light shielding release position for releasing the shielding, and an actuator configured to move the movable shade between the light shielding position and the light shielding release position are disposed between the light emitting element and the projection lens.

In this case, if the heat sink is configured to have a plurality of first flat portions in which a plurality of flange portions are press-contacted, and the first flat portions are formed at positions offset from regions extending from a light source supporting region of the heat sink, which supports the light emitting element, to a surface on the opposite side of the heat sink in a direction orthogonal to the light source supporting region, the following operational effects can be obtained.

That is, since the jig for caulking can be configured to receive the pressing force at the time of caulking at a position deviated from the light source supporting region, an excessive force can be prevented from acting on the light source supporting region, and the positional accuracy of the light emitting element can be prevented from being lowered.

In this case, if the heat sink is configured such that the second flat portion extending in parallel with the first flat portion is formed on the surface of the opposite side to at least one of the plurality of first flat portions, the second flat portion can effectively receive the pressing force at the time of caulking fixation.

Drawings

Fig. 1 is a side sectional view showing a vehicle lamp provided with a lamp unit according to an embodiment of the present invention.

Fig. 2 is a plan view showing the lamp unit.

Fig. 3 is a detailed view of section iii of fig. 1.

Fig. 4 is a view in the direction iv of fig. 3.

Fig. 5 is a view in the direction v of fig. 4.

Figure 6 is a detailed cross-sectional view of line vi-vi of figure 2.

Fig. 7 is an exploded view of the lamp component shown in fig. 6, and is the same as fig. 6.

Fig. 8 shows a first modification of the above embodiment, and is the same as fig. 1.

Fig. 9 is a perspective view of a main portion of the lamp unit according to the first modification example, viewed obliquely from below and forward.

Fig. 10 shows a second modification of the above embodiment, and is similar to fig. 9.

The symbols in the drawings have the following meanings:

10. 110, 210-Lamp Unit

12-projection lens

14-light emitting element

14 a-light emitting surface

16-reflector

16 a-reflecting surface

16 b-flange part

16c, 16d, 22c, 22d, 28Ba1, 28Ba 2-engaging holes

16e, 22 g-abutting part

18-Movable Shield

18 a-upper edge

20-light source supporting member

20 a-terminal part

22. 122, 222-radiator

22a, 122a, 222 a-upper face

22a1, 122a1, 222a1 — light source support region

22a 2-recess

22a 3-upper projection surface

22a 4-front horizontal plane

22 b-locating pin

22 e-heat sink

22 f-thin wall part

24-lens holder

24A-frame body

24B-arm part

24C-joint part

24D-flange part

24Da, 24Dc, 122 i-riveting pin

24Db, 24Dd, 122 j-locating pin

26-rotating pin

28-driver

28A-driver body

28B-Main body support Member

28 Ba-flange part

30-supply fittings

32-insulating part

32 a-opening part

32 b-flange part

32 c-engaging hole

32d connector part

32d 1-rectangular hole

32d 2-recess

34-bus bar electrode

34 a-terminal plate

34 b-tabletting

34 c-terminal pin

40. 42-screw

100. 200-vehicle lamp

102 lamp body

104-light-transmitting cover

122h, 222 h-first plane part

122i, 222 i-riveting pin

122j, 222 j-locating pin

122k, 222 k-second planar section

Ax-optic axis

F-rear focus

Detailed Description

The present invention will be described with reference to the drawings, and various limitations are imposed on the components, types, combinations, shapes, relative arrangements, and the like in the following embodiments.

Fig. 1 is a side sectional view showing a vehicle lamp 100 provided with a lamp unit 10 according to an embodiment of the present invention. Fig. 2 is a plan view showing the lamp unit 10.

In the above-described drawings, the direction indicated by X is the "cell front", the direction indicated by Y is the "left direction" (the "right direction" in the front view of the cell) orthogonal to the "cell front", and the direction indicated by Z is the "upper direction". The same applies to other figures.

The vehicle lamp 100 is a headlamp provided at a front end portion of a vehicle, and is configured to house the lamp unit 10 in a state in which an optical axis is adjusted so that a front-rear direction thereof (i.e., a unit front-rear direction) coincides with a vehicle front-rear direction in a lamp chamber formed by a lamp body 102 and a translucent cover 104.

The lamp unit 10 includes a projection lens 12, a light emitting element 14 disposed on the unit rear side of a rear focal point F of the projection lens 12, a reflector 16 disposed so as to cover the light emitting element 14 from above and reflect light emitted from the light emitting element 14 toward the projection lens 12, and a movable shade 18 disposed between the light emitting element 14 and the projection lens 12.

The projection lens 12 is a plano-convex aspherical lens having a convex front surface and a flat rear surface, and has an optical axis Ax extending in the unit front-rear direction. The projection lens 12 projects a light source image formed on a rear focal plane including a rear focal point F as a reverse image onto a virtual vertical screen in front of the lamp.

Fig. 3 is a detailed view of section iii of fig. 1. Fig. 4 is a view in the direction iv of fig. 3. Fig. 5 is a view in the direction v of fig. 4. In fig. 4, the reflector 16 is shown in a partially cut-away state.

As shown in fig. 3 to 5, the light emitting element 14 is a white light emitting diode and has a horizontally long rectangular light emitting surface 14 a. The light emitting element 14 is supported by a metal (e.g., aluminum die-cast) heat sink 22 via a light source support member 20 in a state where the light emitting surface 14a faces upward below the optical axis Ax.

The light source supporting region 22a1 of the light source supporting member 20 is supported on the upper surface 22a of the heat sink 22, and is formed in a planar shape so as to protrude upward with respect to the peripheral region thereof. The light source supporting region 22a1 is formed with an inclined surface inclined downward toward the cell rear side together with its peripheral region, and thereby the light emitting surface 14a of the light emitting element 14 is disposed in a state of being inclined upward and rearward.

On the upper face 22a of the heat sink 22, a power supply fitting 30 (to be described later) for supplying power to the light emitting element 14 is mounted.

The reflecting surface 16a of the reflector 16 is formed as a curved surface having a substantially elliptical surface shape with the light emission center of the light emitting element 14 as a first focal point. The reflecting surface 16a is formed in an elliptical shape having a vertical cross section along the major axis, with a point slightly forward of the rear focal point F being a second focal point, and the eccentricity thereof is set to gradually increase from the vertical cross section to the horizontal cross section. The reflector 16 is supported at both right and left sides thereof by a lens holder 24 (to be described later).

The projection lens 12 is made of a resin member (for example, a member made of polycarbonate resin or a member made of 9T nylon resin), and is supported by the lens holder 24 at its outer peripheral flange portion.

The lens holder 24 includes a holder main body 24A for supporting the projection lens 12, a pair of left and right arm portions 24B formed to extend from both left and right side portions of the holder main body 24A toward the unit rear, and a coupling portion 24C for coupling rear end portions of the pair of left and right arm portions 24B. At this time, the pair of left and right arm portions 24B are formed at the rear end portions thereof so as to be bent toward the optical axis Ax, and the coupling portion 24C is formed so as to surround the reflector 16 in a substantially arc shape. The lens holder 24 is supported by the heat sink 22 at a position near the rear end portions of the pair of left and right arm portions 24B (this will be also described later).

As shown in fig. 1, the movable shield 18 is rotatably supported on the heat sink 22 below the optical axis Ax by a rotation pin 26 extending in the left-right direction. The movable shade 18 is formed to extend obliquely upward from its front end portion toward the unit rear, and its upper end edge 18a is formed to extend horizontally in different levels from left to right.

The movable shade 18 is driven by an actuator 28 supported by the heat sink 22, and can take a light blocking position (a position indicated by a solid line in fig. 1) for blocking a part of the light reflected from the reflector 16 of the projection lens 12 and a light blocking release position (a position indicated by a two-dot chain line in fig. 1) for releasing the blocking by rotating a predetermined angle downward from the light blocking position.

The actuator 28 includes an actuator main body 28A and a metallic main body support member 28B that covers the actuator main body 28A and supports the actuator main body 28A, and a pair of front and rear flange portions 28Ba are formed on the main body support member 28B. The actuator 28 is fastened and fixed to the heat sink 22 by screws 42 at the respective flange portions 28 Ba.

The driver 28 is driven when a beam switching switch, not shown, is operated. Thus, the lamp unit 10 performs low beam irradiation when the movable shade 18 is in the light blocking position, and performs high beam irradiation when the movable shade 18 is in the light blocking release position.

As shown in fig. 4, the light source support member 20 for supporting the light emitting element 14 has a horizontally long rectangular external shape in a plan view, and on the external shape, a cathode electrode and an anode electrode of the light emitting element 14, and a pair of right and left terminal portions 20a electrically connected to each other are arranged at positions on both right and left sides of the light emitting element 14.

The power supply metal fitting 30 is formed as an insert molded product, and a pair of left and right bus bar electrodes 34 for electrically connecting the light emitting element 14 to the insulating member 32 formed so as to surround the light source supporting member 20 are embedded in a state in which a part of each of the bus bar electrodes is exposed.

The insulating member 32 is a plate-like member having an outer shape of a horizontally long rectangular shape in a plan view, and has an opening 32a of a horizontally long rectangular shape formed at a center position in a left-right direction thereof.

The insulating member 32 includes a pair of left and right flange portions 32b projecting horizontally from both left and right side portions thereof, and each flange portion 32b is fastened and fixed to the upper surface 22a of the heat sink 22 by a screw 40. At this time, a pair of left and right positioning pins 22b are formed on the upper surface 22a of the heat sink 22, and engagement holes 32c that engage with the pair of left and right positioning pins 22b are formed in the pair of left and right flanges 32b of the insulating member 32, respectively. One of the pair of left and right engaging holes 32c is formed in a circular shape, and the other is formed in a horizontally long rectangular shape.

The pair of left and right bus bar electrodes 34 include a pair of left and right terminal pieces 34a protruding toward the opening 32a, and are electrically connected to the light emitting diode 22 by coming into contact with the pair of left and right terminal portions 20a of the light source support member 20.

The pair of left and right bus bar electrodes 34 includes a pair of front and rear pressing pieces 34b protruding toward the opening 32a, and these press pieces are brought into contact with the upper surface of the light source support member 20 to position the light emitting diode 22.

At this time, the terminal pieces 34a and the pressing pieces 34b are configured as elastic pieces that elastically press the light source support member 20 from above.

The insulating member 32 includes a connector portion 32d protruding from the rear portion thereof toward the rear of the unit.

The connector portion 32d is formed to extend from the rear end position of the reflector 16 to the unit rear side, and is opened to the unit rear side. At this time, the connector portion 32d is formed at the center position of the connection position of the insulating member 32 and the heat sink 22 on both right and left sides (i.e., a position directly below the optical axis Ax). The connector portion 32d is formed to extend upward and downward on the unit rear side of the rear end position of the reflector 16.

A rectangular hole 32d1 extending in the cell front-rear direction is formed in the upper wall portion of the connector portion 32d, and rectangular recesses 32d2 are formed in both left and right side wall portions of the connector portion 32 d.

In the internal space of the connector portion 32d, the terminal pins 34c of the pair of left and right bus electrodes 34 protrude rearward of the cell. The pair of left and right terminal pins 34c are each formed in a plate shape, and are arranged such that the plate surface thereof faces in the vertical direction inclined toward the unit rear side with respect to the vertical direction (i.e., in the second direction orthogonal to the first direction in which the pair of left and right terminal pins 34c are arranged). A connector (not shown) of the power supply wiring is inserted into the internal space of the connector portion 32d, and the power supply fitting 30 and the power supply wiring are electrically connected by being fitted into the rectangular hole 32d1 and the pair of left and right recesses 32d 2.

The heat sink 22 is formed so that its rear end position is substantially the same as the rear end edge of the connector portion 32 d. On an upper surface 22a of the rear end portion of the heat sink 22 (i.e., a surface on which the power supply accessory 30 is placed), a recess 22a2 having a shape along the shape of the lower end portion of the connector portion 32d is formed. Further, a plurality of fins 22e are formed in the rear region of the heat sink 22 to extend downward.

In the heat sink 22, a portion to which the lens holder 24 is attached is formed as the thin portion 22f, and the upper surface thereof is formed as an upper projecting surface 22a3 projecting upward from the other portion of the upper surface 22 a.

On the other hand, a pair of left and right flange portions 24D for placing on the pair of left and right upper protruding surfaces 22a3 of each heat sink 22 are formed in the vicinity of the rear end portions of the pair of left and right arm portions 24B of the lens holder 24. Each flange portion 24D is formed in a flat plate shape extending obliquely downward toward the unit rear, and the inclination angle thereof is set to the same value as the inclination angle of the upper surface 22a (including the pair of left and right upper protruding surfaces 22a3) of the heat sink 22. The lens holder 24 is fixed to the heat sink 22 by caulking at each flange portion 24D.

The reflector 16 is provided with a pair of left and right flange portions 16b projecting in a flat plate shape in the horizontal direction from the lower end positions of the left and right side portions thereof, and each flange portion 24D of the lens holder 24 is placed on each flange portion 16 b. The reflector 16 is fixed to the lens holder 24 by caulking at each flange portion 16 b.

Fig. 6 is a cross-sectional detail view taken along line VI-VI of fig. 2, showing the mounting structure of the reflector 16 to the lens holder 24 and the mounting structure of the lens holder 24 to the heat sink 22. Fig. 7 is an exploded view of the reflector 16, the lens holder 24, and the heat sink 22, and is the same as fig. 6.

As shown in fig. 6 and 7, a cylindrical caulking pin 24Da and a positioning pin 24Db protruding in a direction perpendicular to the upper surface of each flange portion 24D of the lens holder 24 are formed. At this time, the caulking pin 24Da is formed to have a larger diameter than the positioning pin 24Db in the rear end vicinity of the flange 24D, and the positioning pin 24Db is formed at a position closer to the unit front side than the caulking pin 24 Da.

On the other hand, each flange portion 16b of the reflector 16 is formed with an engagement hole 16c for engaging with the caulking pin 24Da and an engagement hole 16d for engaging with the positioning pin 24 Db. At this time, as shown in fig. 4, one of the pair of left and right engaging holes 16c is formed in a circular shape, and the other is formed in an oblong shape elongated in the lateral direction. One of the pair of left and right engaging holes 16d is formed in a circular shape, and the other is formed in an oblong shape elongated in the lateral direction.

Then, as shown in fig. 7, the caulking pin 24Da and the positioning pin 24Db are inserted into the engagement holes 16c and 16D, respectively, and in a state where the flange portion 16b of the reflector 16 is placed on the upper surface of the flange portion 24D of the lens holder 24, as shown in fig. 6, the tip end portion of the caulking pin 24Da is crushed, and the upper surface of the flange portion 16b is expanded to the periphery of the engagement hole 16c, thereby caulking and fixing the reflector 16 and the lens holder 24. The riveting is performed by hot riveting.

As shown in fig. 6 and 7, a cylindrical caulking pin 24Dc and a positioning pin 24Dd protruding in a direction perpendicular to the lower surface of each flange portion 24D of the lens holder 24 are formed. At this time, the caulking pin 24Dc is formed with a diameter larger than that of the positioning pin 24Dd in the vicinity of the tip end of the flange 24D, and the positioning pin 24Dd is formed at a position closer to the unit rear side than the caulking pin 24 Dc.

As shown in fig. 4, the caulking pin 24Dc and the positioning pin 24Dd are formed in a state displaced to the outer side in the left-right direction than the caulking pin 24Da and the positioning pin 24 Db.

On the other hand, an engagement hole 22c for engaging the caulking pin 24Dc and an engagement hole 22d for engaging the positioning pin 24Dd are formed in each thin portion 22f of the heat sink 22. At this time, as shown in fig. 4, one of the pair of left and right engaging holes 22c is formed in a circular shape, and the other is formed in an oblong shape elongated in the lateral direction. One of the pair of left and right engaging holes 22d is formed in a circular shape, and the other is formed in an oblong shape extending in the lateral direction.

Then, as shown in fig. 7, the caulking pin 24Dc and the positioning pin 24Dd are inserted into the engagement holes 22c, 22D, respectively, and in a state where the flange portion 24D of the lens holder 24 is placed on the upper protruding surface 22a3 of the heat sink 22, as shown in fig. 6, the tip end portion of the caulking pin 24Dc is crushed and expanded to the periphery of the engagement hole 22c on the lower surface of the thin portion 22f, thereby caulking and fixing the lens holder 24 and the heat sink 22. The riveting is also performed by hot riveting.

As shown in fig. 4 and 5, the reflector 16 has an abutting portion 16e that abuts against the heat sink 22 at a portion located on the cell rear side of the two right and left fastening positions with respect to the heat sink 22. The contact portion 16e is formed as a protrusion extending rearward from the lower end of the reflector 16 and then extending downward at a position near the left side of the recess 22a2 of the heat sink 22, and is configured to contact the upper surface 22a of the heat sink 22.

As shown in fig. 2 and 6, the radiator 22 is provided with a pair of left and right front horizontal surfaces 22a4 that are located on the unit front side with respect to the pair of left and right upper protruding surfaces 22a3 and extend along the horizontal surfaces. Further, at the distal end of each front horizontal surface 22a4, a contact portion 22g that contacts the lens holder 24 is formed. The pair of left and right contact portions 22g are formed as protrusions extending upward, and are configured to contact the lower surfaces of the pair of left and right arm portions 24B of the lens holder 24.

Next, the operation of the present embodiment will be explained.

The lamp unit 10 according to the present embodiment is configured to include the heat sink 22 for supporting the light emitting element 14 and the lens holder 24 for supporting the projection lens 12 as a lamp unit configured to make the light emitted from the light emitting element 14 reflected by the reflector 16 enter the projection lens 12, and the reflector 16 is fixed to the lens holder 24 by caulking at two left and right positions thereof, and the heat sink 22 is also fixed to the lens holder 24 by caulking at two left and right positions thereof, so that the number of parts of the lamp unit 10 can be reduced, and the cost of the lamp unit 10 can be reduced.

Further, since the work space required for the caulking fixation is smaller than the work space required for the screw tightening fixation, the size of the lamp unit 10 can be reduced as compared with the conventional lamp unit 10 in which the lens holder 24 and the heat sink 22 are fixed by screws.

Further, since the caulking fixation occupies a smaller space than the screw fixation, the size of the lamp unit 10 can be reduced in this respect.

As described above, according to the present embodiment, in the projection type lamp unit 10 provided with the reflector 16, the number of parts can be reduced and the size can be reduced.

In addition, in the present embodiment, since the caulking fixation of the reflector 16 and the caulking fixation of the heat sink 22 are performed from both the upper and lower sides with respect to the lens holder 24, a working space for performing the respective caulking fixation can be easily secured, and further downsizing of the lamp unit 10 can be achieved.

In this case, in the present embodiment, the lens holder 24 is made of a resin member, and both the caulking fixation of the reflector 16 and the caulking fixation of the heat sink 22 are performed by thermal caulking, so that the work efficiency of the caulking fixation can be improved.

In the lens holder 24 of the present embodiment, the positioning pins 24Db are formed near the caulking pins 24Da for caulking and fixing the reflector 16, and the positioning pins 24Dd are formed near the caulking pins 24Dc for caulking and fixing the heat sink 22, so that the positioning accuracy of the reflector 16 and the heat sink 22 with respect to the lens holder 24 can be improved.

Furthermore, in the present embodiment, since the heat sink 22 is configured to have the abutting portion 22g abutting against the lens holder 24 at a portion of the heat sink 22 located on the unit front side of the caulking-fixing position, the support of the heat sink 22 with respect to the lens holder 24 can be performed by at least a three-point support structure, and the positioning accuracy of the projection lens 12 can be improved. Therefore, the positional relationship accuracy between the light emitting element 14 supported by the heat sink 22 and the reflector 16 and the projection lens 12 supported by the lens holder 24 can be improved, and the optical characteristics of the lamp unit 10 can be improved.

In the present embodiment, since the caulking of the reflector 16 is performed on the unit rear side of the caulking of the heat sink 22, the reflector 16 can be positioned with high accuracy, and the optical characteristics of the lamp unit 10 can be improved.

In the above embodiment, the caulking position of the lens holder 24 and the heat sink 22 is described as being displaced to the outside in the left-right direction as compared with the caulking position of the reflector 16 and the lens holder 24, but the caulking position may be set to the same position in the left-right direction or displaced to the inside in the left-right direction.

In the above embodiment, the caulking of the reflector 16 and the caulking of the heat sink 22 are performed by the hot caulking, but either or both may be configured to be cold-caulked, and in this case, the caulking, etc. may be employed.

In the above embodiment, the lamp unit 10 is described as a lamp unit for vehicle mounting, but may be used for applications other than vehicle mounting.

Next, a modified example of the above embodiment will be explained.

First, a first modification of the above embodiment will be described.

Fig. 8 shows a vehicle lamp 200 provided with the lamp unit 110 according to the present modification, and is the same as fig. 1. Fig. 9 is a perspective view of a main part of the lamp unit 110 viewed from obliquely below and forward.

As shown in fig. 8 and 9, the basic configuration of this modification is the same as that of the above embodiment, but the support structure of the actuator 28 is partially different from that of the above embodiment.

That is, in the present modification, the actuator 28 is fixed and supported to the heat sink 122 by caulking.

Specifically, as shown in fig. 9, the front end portion of a pair of front and rear caulking pins 122i protruding from a pair of front and rear first flat surface portions 122h formed on the heat sink 122 is crushed in a state inserted into engagement holes 28Ba1 formed in a pair of front and rear flange portions 28Ba of the body support member 28B of the actuator 28, whereby the body support member 28B of the actuator 28 is caulked and fixed to the heat sink 122. The riveting is performed by cold riveting.

Further, positioning pins 122j are formed at positions close to the caulking pins 122i in the first flat surface portions 122h of the heat sink 122, and the actuator 28 is accurately positioned with respect to the heat sink 122 by inserting the positioning pins 122j into the engagement holes 28Ba2 formed in the flange portions 28 Ba.

At this time, one of the pair of front and rear engaging holes 28Ba1 is formed in a circular shape, and the other is formed in an oblong shape elongated in the lateral direction. One of the pair of front and rear engaging holes 28Ba2 is formed in a circular shape, and the other is formed in an oblong shape elongated in the lateral direction.

The front and rear pair of first flat surface portions 122h are formed to extend along inclined surfaces inclined downward toward the rear of the unit so as to be flush with each other. At this time, each first flat portion 122h is formed to extend in parallel with the light source supporting region 122a1 of the upper surface 122a of the heat sink 122 and the peripheral region thereof.

Along with this, the main body support member 28B of the actuator 28 is also formed such that a pair of front and rear flange portions 28Ba extend along inclined surfaces inclined downward toward the unit rear.

The pair of front and rear first flat portions 122h are formed at positions offset to the front side of the cell from regions extending from the light source supporting region 122a1 to the surface on the opposite side of the heat sink 122 in the direction orthogonal to the light source supporting region 122a1 (i.e., regions located inside the front and rear two straight lines indicated by the two-dot chain lines in fig. 9).

The heat sink 122 is formed such that a surface of the heat sink opposite to the first flat portion 122h located on the rear side of the cell is a second flat portion 122k constituting a region located on the front side of the cell of the light source supporting region 122a1, out of the peripheral region of the light source supporting region 122a1, and extends parallel to the first flat portion 122 h.

By adopting the configuration of the present modification, the number of components of the lamp unit 110 can be further reduced.

In the present modification, a pair of front and rear flange portions 28Ba are provided, and each flange portion 28Ba is fixed by caulking to the heat sink 122 as the actuator 28 for moving the movable shade 18 between the light blocking position and the light blocking release position, so that the number of parts of the lamp unit 110 can be further reduced.

In the present modification, since the pair of front and rear first flat surface portions 122h to which the pair of front and rear flange portions 28Ba are fixed by caulking are formed at positions offset from the regions extending from the light source supporting region 122a1 of the heat sink 122 to the surface on the opposite side of the heat sink 122 in the direction orthogonal to the light source supporting region 122a1, the following operational effects can be obtained.

That is, since the jig for caulking can be configured to receive the pressing force at the time of caulking at a position deviated from the light source supporting region 122a1, an excessive force can be prevented from acting on the light source supporting region 122a1, and the positional accuracy of the light emitting element 14 can be prevented from being lowered.

Further, since the surface of the heat sink 122 opposite to the first flat surface 122h located on the unit rear side is formed as the second flat surface 122k extending in parallel with the first flat surface 122h, the second flat surface 122k can effectively receive the pressing force at the time of caulking fixation.

Next, a second modification of the above embodiment will be described.

Fig. 10 shows a main part of a lamp unit 210 according to the present modification, and is the same as fig. 9.

As shown in fig. 10, the basic configuration of this modification is the same as that of the first modification, but the caulking position of the actuator 28 to the heat sink 222 is different from that of the first modification.

That is, in this modification, the actuator 28 is fixed to the heat sink 222 by caulking the pair of front and rear flange portions 28Ba, and this caulking is performed by cold caulking.

Specifically, the body support member 28B of the actuator 28 is caulked and fixed to the heat sink 222 by collapsing the front end portion of the front and rear pair of caulking pins 222i protruding from the front and rear pair of first flat surface portions 222h formed in the heat sink 222 in a state where the engagement holes 28Ba1 formed in the front and rear pair of flange portions 28Ba of the body support member 28B of the actuator 28 are inserted.

Further, positioning pins 222j are formed at positions close to the caulking pins 222i in the first flat surface portions 222h of the heat sink 222, and the actuators 28 are accurately positioned with respect to the heat sink 222 by inserting the positioning pins 222j into the engagement holes 28Ba2 formed in the flange portions 28 Ba.

The front and rear pair of first flat portions 222h are formed to extend along inclined surfaces inclined downward toward the rear of the unit so as to be flush with each other. On the other hand, the regions around the light source supporting region 222a1 on the upper surface 222a of the heat sink 222 on both the front and rear sides of the light source supporting region 222a1 form a pair of front and rear second flat portions 222k facing the pair of front and rear first flat portions 222 h. At this time, a pair of front and rear first flat portions 222h and a pair of front and rear second flat portions 222k extend in parallel with each other.

Even in the case of the configuration of the present modification, since the jig for caulking is configured to receive the pressing force at the time of caulking at a position deviated from the light source supporting region 122a1 (i.e., at a position outside the front and rear two straight lines indicated by the two-dot chain line in fig. 10), an excessive force does not act on the light source supporting region 122a1, and the positional accuracy of the light emitting element 14 cannot be lowered.

In particular, since the heat sink 222 of the present modification is formed to extend in parallel at a position where the pair of front and rear first flat portions 222h and the pair of front and rear second flat portions 222k face each other, the pressing force at the time of caulking by the caulking jig can be more effectively received. Therefore, an excessive force can be easily not applied to the light source supporting region 222a1, and the positional accuracy of the light emitting element 14 can be further reliably prevented from being lowered.

In the above embodiments and modifications, the numerical values indicated as the parameters are merely examples, and may be set to appropriately different numerical values.

The embodiments of the present invention have been described above with reference to the drawings, but the present invention is not limited to the above embodiments. The technical idea of the present invention can be changed, and they all belong to the protection scope of the present invention.

Claims

1. A lamp unit including a projection lens, a light emitting element disposed on a unit rear side of the projection lens, and a reflector for reflecting light emitted from the light emitting element toward the projection lens, characterized in that:

2. A lighting unit as recited in claim 1, wherein:

the riveting of the reflector and the riveting of the heat sink are performed from the upper and lower sides with respect to the lens holder.

3. A lighting unit as recited in claim 1, wherein:

the lens holder is composed of a resin member;

the rivet fixing of the reflector and the rivet fixing of the heat sink are performed by thermal caulking.

4. A lighting unit as recited in claim 2, wherein:

the lens holder is composed of a resin member;

5. A luminaire unit as claimed in any one of claims 1 to 4, characterized in that:

the riveting of the reflector is performed on the unit rear side compared to the riveting of the heat sink.

6. A luminaire unit as claimed in any one of claims 1 to 4, characterized in that:

the heat sink is provided with a contact portion that contacts the lens holder at a position located on the unit front side of the press-fitting fixing position of the heat sink.

7. A luminaire unit as claimed in any one of claims 1 to 4, characterized in that:

a movable shade and an actuator are arranged between the light emitting element and the projection lens, the movable shade is configured to be capable of being positioned at a light blocking position for blocking a part of the reflected light from the reflector and a light blocking release position for releasing the blocking, and the actuator moves the movable shade between the light blocking position and the light blocking release position;

the driver is provided with a plurality of flange parts;

the actuator is fixed to the radiator by caulking at each of the flange portions.

8. The lamp unit of claim 7, wherein:

the radiator is provided with a plurality of first plane parts for pressing and connecting the plurality of flange parts;

each of the first flat portions is formed at a position deviated from a region extending from a light source supporting region of the heat sink supporting the light emitting element toward a direction orthogonal to the light source supporting region up to a surface on the opposite side of the heat sink.

9. The lamp unit of claim 8, wherein:

the surface of the heat sink on the opposite side to at least one of the plurality of first flat portions is formed as a second flat portion extending in parallel with the first flat portion.