Projector-type lamp unit for vehicle

A projector-type lamp unit including a first reflecting surface for reflecting and condensing light emitted from an LED toward a projection lens disposed in the forward direction than the LED, a second reflecting surface for reflecting a part of the reflected light from the first reflecting surface toward the projection lens, and a design portion disposed between the second reflecting surface and the projection lens and continuing to the second reflecting surface. The first reflecting surface, the second reflecting surface and the design portion form a one-piece reflection mirror unit.

The present invention claims foreign priority from Japanese patent application no. 2005-124108, filed on Apr. 21, 2005, the content of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a lamp unit used for a vehicle lamp and, in particular, relates to a projector-type lamp unit for a vehicle, which employs a semiconductor light emitting element as a light source.

2. Description of the Related Art

As a lamp for a vehicle such as a headlamp, for example, there are a projector-type and a paraboloidal reflector-type. The projector-type vehicle lamp is configured in a manner that a light emitted from a light source disposed on an optical axis is reflected toward the forward direction by a reflector and is converged close to the optical axis. The reflected light is irradiated in the forward direction of the lamp via a projection lens disposed on the forward side of the reflector. On the other hand, the paraboloidal reflector-type vehicle lamp is configured to include a light source disposed on an optical axis and a reflector, which is formed so as to have, as a reference surface, a rotating paraboloidal surface having a focal point near the light source. A light emitted from the light source is reflected toward the forward direction by the reflector as a parallel light so that the reflected light is irradiated in the forward direction of the lamp.

The projector-type vehicle lamp is smaller in the diameter of the reflector as compared with that of the paraboloidal reflector-type vehicle lamp. Therefore, the projector-type vehicle lamp can be miniaturized in its size. However, in the case where the discharge light emitting portion of a discharge bulb or the filament of a halogen lamp is used as the light source, in order to control the reflection of light from the light source suitably or to secure a space for attaching the light source, the reflector is required to have a certain size even for the projector-type vehicle lamp. Further, since a heat value of the light source is large, the size of the reflector is required to be set in view of the influence of the heat. Thus, it is difficult to further miniaturize the lamp.

In view of above, there is proposed a lamp which employs an LED (light emitting diode), for example, as a semiconductor light emitting element for a light source (for example, see Japanese Patent Unexamined Publication JP-A-2003-317513, pages 2 to 5 and FIG. 3).

When the light source is configured by an LED, since the light source can be treated as an almost point light source, the diameter of the reflector can be made small. Further, since it is not required for the reflector to secure a large attachment space nor to take the influence of the heat from the LED into consideration, the lamp can be made smaller as compared with the case where the discharge light emitting portion of the discharge bulb or the filament of the halogen lamp is used as the light source.

In the related art, since the reflector forming first and second reflecting surfaces and a light controlling member forming a third reflecting surface are formed by different members, the positional accuracy of the respective reflecting surfaces is not sufficient for an LED light source. Further, when the lamp is seen from the forward side thereof in the turning-off state, the outer appearance is not good since the members in an area outside of the reflecting surface area within the lamp can be seen.

SUMMARY OF THE INVENTION

According to a first aspect of the invention, a projector-type lamp unit for a vehicle includes a projection lens; a semiconductor light emitting element as a light source; a first reflecting surface, which reflects and condenses a light emitted from the light source toward the projection lens disposed in a forward direction from the light source; a second reflecting surface which reflects a part of the light reflected from the first reflecting surface toward the projection lens; and a design portion disposed between the second reflecting surface and the projection lens and connected to the second reflecting surface. The first reflecting surface, the second reflecting surface, and the design portion are formed as a one-piece structure.

DESCRIPTION OF THE EXEMPLARY EMBODIMENT

Hereinafter, an exemplary embodiment of the invention will be explained with reference to the drawings. As shown inFIGS. 1 to 6, for example, the vehicle lamp10includes both a projector-type lamp unit14having an LED12(semiconductor light emitting element) as a first light source, a reflection-type (e.g., paraboloidal reflector-type) lamp unit18having an LED16as a second light source. The projector-type lamp unit14and the reflection-type lamp unit18are housed within a lamp chamber26having a front face cover20(outer lens), a lamp body22, and a rear face cover24. The reflection-type lamp unit18is disposed just beneath the projector-type lamp unit14. The lower side of the projector-type lamp unit18almost contacts the reflection-type lamp unit14. The vehicle lamp10is not limited to a vehicle lamp of a particular kind but may be used for a head lamp, an adverse weather lamp, a bending lamp, etc. A semiconductor laser may be used in place of the LED as the semiconductor light emitting element.

The projector-type lamp unit14includes the LED12as the first light source, a reflector28, a coupling member30and a projection lens32. As shown inFIG. 8, for example, the LED12(semiconductor light emitting element) is a white LED having an LED chip12awith a square shape (each side being approximately 1 mm), a cap12bof substantially hemisphere shape covering the LED chip12a, and metal wires12c,12d. The LED12is disposed on a heat conductive and electrically insulating board34(ceramics, for example)34in a manner that the LED′ s irradiation face (irradiation direction) is provided in a direction almost perpendicular to the optical axis Ax of the projector-type lamp unit14. That is, as shown inFIG. 4, the LED12is disposed substantially on the optical axis Ax. The LED chip12aand conductive patterns34a,34b(e.g., metal thin films) are formed on the heat conductive and electrically insulating board34in a manner that the LED chip is sandwiched between the conductive patterns34a,34b. The conductive pattern34ais coupled to the anode of the LED chip12avia the metal wire12c, and the conductive pattern34bis coupled to the cathode of the LED chip12avia the metal wire12d. The heat conductive and electrically insulating board34is fixed to the fixing portion220of the lamp body22. The board34is supported by an attachment35made of resin, a spring plate36, etc. (seeFIG. 13).

The fixing portion220is provided by extending the same material of the body22to formed an almost flat plate shape, by using a die cast of metal consisting mainly of aluminum. The fixing portion220is disposed at the upper portion on the inner peripheral side of the lamp body22(seeFIGS. 12 and 13). That is, the fixing portion220made of metal is provided within the lamp body22and is linked with the lamp body22. The fixing portion220is provided with a setting surface220afor setting the heat conductive and electrically insulating board34, portions220b,220cfor attaching the attachment35thereon, and concave portions220d,220e,220ffor supporting the spring plate36.

The attachment35includes a supporting portion35aand a connector35bserving as a feeding portion, as shown inFIG. 8. The supporting portion35ais formed in an almost flat plate shape and provided with an opening35cat almost the center portion thereof. Coupling terminals35d,35eare disposed at opposing sides of the opening35c. Each of the coupling terminals35d,35eis formed in a curved shape by using a plate member made of metal. A part of each of the coupling terminals is buried within the attachment35and electrically coupled to the connector35b. The attachment35is provided at its lower portion side with a projection35fand concave portions35g,35h, which support an auxiliary attachment37. The auxiliary attachment37is formed in an almost U-shape by using the resin material and is provided with projections37a,37bfor supporting the heat conductive and electrically insulating board34.

In the case of supporting the LED12by the attachment35, as shown inFIG. 9, the heat conductive and electrically insulating board34is disposed on the lower portion side of the attachment35. The heat conductive and electrically insulating board34is pushed up toward the opening35cfrom the lower portion side of the attachment35so that the conductive patterns34a,34bon the heat conductive and electrically insulating board34contact with the coupling terminals35d,35e, respectively, and the LED12protrudes from the opening35c. Thereafter, when the tip end side portions of the auxiliary attachment37are inserted into the portions35g,35h, respectively, the base end side of the auxiliary attachment37is supported by the projection35f. Thus, as shown inFIGS. 10 and 11, the heat conductive and electrically insulating board34is pushed up toward the coupling terminals35d,35ein a state that the lower portion side of the insulation board34is supported by the projections37a,37bof the auxiliary attachment37. Therefore, the conductive patterns34a,34bon the heat conductive and electrically insulating board34contact the coupling terminals35d,35e, respectively, with a pressure. The coupling terminal35dis coupled to the anode of the LED chip12avia the conductive pattern34aand the metal wire12c, whilst the coupling terminal35eis coupled to the cathode of the LED chip12avia the conductive pattern34band the metal wire12d.

In the case of fixing the attachment35attached with the LED12to the fixing portion220of the lamp body22, as shown inFIGS. 12 and 13, the connector35bof the attachment35is attached within the concave portion220band the left side of the supporting portion35ais attached within the concave portion220c, whereby the heat conductive and electrically insulating board34contacts the setting surface220a. Next, the tip end side portions of the spring plate36are inserted into the concave portions220d,220eof the fixing portion220and the base end side of the spring plate36is inserted into the concave portion220fof the fixing portion220, whereby the elastic force of the spring plate36acts on the attachment35to the vertically downward direction. Thus, the entire attachment35is attached with a pressure to the fixing portion220, and the heat conductive and electrically insulating board34is attached with a pressure to the setting surface220a. That is, the LED12contacts, at a rear surface side of the light emitting surface thereof, the setting surface220avia the heat conductive and electrically insulating board34and is fixed thereto. Since the setting surface220ais integrally formed with the fixing portion220of the lamp body22made of aluminum, heat generated from the LED12can be efficiently radiated via the heat conductive and electrically insulating board34, the setting surface220a, the fixing portion220, and the lamp body22.

The first reflector28(polycarbonate, for example) is formed almost in a dome shape and is disposed above the LED12. The reflector28is subjected at its surface to vapor deposition using aluminum. Therefore, the first reflector28has a first reflecting surface28a, which reflects light emitted from the LED12in the forward direction so as to be condensed near the optical axis Ax. The first reflecting surface28ais formed in an almost ellipsoidal shape having the optical axis Ax as the center axis thereof and serves as a reflecting surface, which reflects and condenses the light emitted from the LED12toward the projection lens32disposed at the front direction with respect to the LED12. The first reflecting surface28ais set in a manner that its sectional shape including the optical axis Ax is set to an almost elliptical shape and the eccentricity of the elliptical shape becomes larger gradually from the vertical section thereof toward the horizontal section thereof. The LED12is disposed at a first focal point F1of the ellipse forming the vertical section of the first reflecting surface28a(seeFIG. 6). Thus, the first reflecting surface28acan reflect light emitted from the LED12in the forward direction so as to be condensed near the optical axis Ax. In this case, the first reflecting surface28ais set to converge the reflected light almost on the second focal point F2of the ellipse in the vertical section including the optical axis Ax.

The coupling member30includes a flat portion38disposed at the almost lower side of the optical axis Ax and a semi-tubular design portion40of an almost bucket shape (seeFIG. 14). The coupling member30is formed by polycarbonate so as to be integrally molded with the reflector28and is disposed between the LED12and the projection lens32. The flat portion38is integrally coupled to the reflector28and fixed to the lamp body22by screws. The end portion on the front side of the design portion40is melted and adhered by using ultrasonic bonding to the projection lens32having the contour of an almost hemispherical shape. Each of the flat portion38and the design portion40is subjected at its surface to vapor deposition using aluminum. As shown inFIG. 14, the flat portion38is provided with a second reflecting surface38a, which reflects a part of the reflected light from the first reflecting surface28aof the reflector28to the forward direction, that is, toward the projection lens32.

The design portion40is disposed along the inclined downward direction from the boundary between the design portion and the flat portion38so as to couple between the edge of the flat portion38and the lower portion side of the projection lens32. The design portion40is configured to cover a reflected light path which conducts the reflected light from the first reflecting surface28aof the reflector28to the projection lens32. That is, the design portion40, which is connected to the second reflecting surface38a, is disposed between the second reflecting surface38aand the projection lens32. The design portion is formed in a semi-tubular almost bucket shape adjacent to and along the reflected light path directed from the first reflecting surface28ato the outer peripheral line of the projection lens32, of almost hemispherical shape so as to cover the reflected light from the first reflecting surface28awithout shielding. Thus, the reflected light from the first reflecting surface28acan be effectively entered into the projection lens32. Further, since the rear side space of the reflected light path can be used effectively, the head lamp can be miniaturized. Further, the portion near the boundary portion between the flat portion38and the design portion40is set to the second focal point F2. Furthermore, the boundary portion between the second reflecting surface38aof the flat portion38and the design portion40is formed so as to have a predetermined cut-off line in the light distribution pattern of the vehicle lamp10. That is, the boundary portion between the second reflecting surface38aof the flat portion38and the design portion40serves as a shade for shielding a part of the reflected light from the first reflecting surface28a, whereby the beam irradiated from the projector-type lamp unit14can form a light distribution pattern P1having a cut-off line CL1like the light distribution pattern of an adverse weather lamp etc. as shown inFIG. 15, for example.

In this case, a light shielding end face of the shade is extended toward the rear direction along the optical axis Ax thereby to form the second reflecting surface38awhich reflects the reflected light from the first reflecting surface28atoward a predetermined direction so that the light to be shielded originally by the shade can be effectively used as an irradiation light beam. Thus, the light beam to be used for the projector-type lamp unit14can be further increased. Further, the boundary portion between the second reflecting surface38aand the design portion40are formed to have the configurations so as to form the cut-off line CL1in the light distribution pattern of the lamp and also serve as the shade, it is not necessary to provide the shade as an independently provided part.

The projection lens32is formed substantially in a hemisphere shape (i.e., dome shape) by using translucent resin such as polycarbonate. The projection lens32is disposed on the rear surface side of the front face cover20, whereby the light reflected from the first reflecting surface28aand transmitted to the design portion40passes in the forward direction through the projection lens32(seeFIG. 14). In this case, much of the light reflected from the first reflecting surface28apasses through the lower half area of the projection lens32and is irradiated on the front face cover20. On the other hand, a part of the light reflected from the first reflecting surface28ais reflected by the second reflecting surface38aand passes through almost the upper half area of the projection lens32and is irradiated on the front face cover20.

According to the projector-type lamp unit14of the embodiment, the reflector28, and the coupling member30are formed as a one-piece structure. That is, a reflection mirror unit42of the projector-type lamp unit14is a one-piece structure including the first reflecting surface28a, the second reflecting surface38a, and the design portion40. By this structure, the positional accuracy of the first reflecting surface28aand the second reflecting surface38acan be enhanced. Further, the light distribution efficiency can be improved and the number of parts can be reduced. Furthermore, since the projection lens32is fixed to the reflection mirror unit42, the positional accuracy of the reflection mirror unit42and the projection lens32can be enhanced and the light distribution efficiency can be further improved.

The projector-type lamp unit14also may be configured without a projection lens32. In this case, at the time of assembling the vehicle lamp10, the projection lens32may be disposed at a predetermined position on the forward side of the projector-type lamp unit14along the optical axis Ax.

On the other hand, as shown inFIGS. 3 to 6, the reflection-type lamp unit18is configured by the LED16and a reflector44. As shown inFIG. 8, the LED16(semiconductor light emitting element) is configured by, as the second light source, a white LED having an LED chip16awith a square shape (each side being almost 1 mm), a cap16bof an almost hemisphere shape covering the LED chip16aand metal wires16c,16d. The LED is disposed on a heat conductive and electrically insulating board (ceramics, for example)46in a manner that its irradiation face (irradiation direction) is provided in an almost vertically downward direction (direction in opposite to the irradiation direction of the LED12). The LED16is disposed in the forward direction with respect to the LED12and in parallel with the optical axis Ax (that is, in the forward side of the lamp). The LED16is disposed at a position in a vacant area which is not used for the transmission of the reflected light from the first reflecting surface28aand is away from the reflected light path conducting the reflected light from the first reflecting surface28aof the projector-type lamp unit14to the projection lens32. The LED chip16aand conductive patterns46a,46b(metal thin films) are formed on the heat conductive and electrically insulating board46in a manner that the LED chip is sandwiched between the conductive patterns. The conductive pattern46ais coupled to the anode of the LED chip16avia the metal wire16c, and the conductive pattern46bis coupled to the cathode of the LED chip16avia the metal wire16d. The heat conductive and electrically insulating board46is fixed to a fixing portion220of the lamp body22in a state of being supported by the attachment35made of resin, the spring plate36, etc. (seeFIG. 13).

The fixing portion222is formed by extending the same material of the lamp body22to formed an almost flat plate shape, by using a die cast of metal consisting mainly of aluminum. The fixing portion222is disposed at the lower portion on the inner peripheral side of the lamp body22so as to oppose to the fixing portion220. The fixing portion222has a configuration that is the reverse of the fixing portion220in both the vertical and horizontal directions. Further, the fixing portion222is configured in a manner that a concave portion etc. for supporting the attachment35and the spring plate36etc. are formed in the forward side of the lamp with respect to the fixing portion220(seeFIG. 6), but the remaining configuration thereof is same as that of the fixing portion220and so the detailed explanation thereof is omitted.

When the attachment35is fixed to the fixing portion222of the lamp body22together with the LED16, the LED16attached to the attachment35contacts, at the rear surface side of the light emission surface thereof, with the fixing portion222and is fixed thereto via the heat conductive and electrically insulating board46. Thus, heat generated from the LED16can be efficiently radiated via the heat conductive and electrically insulating board46, the fixing portion222, and the lamp body22. In this case, since the LED12and the LED16are separately fixed to the fixing portion220and the fixing portion222, respectively, so as to be disposed at different positions on the horizontal plane, each one of the respective LEDs is less influenced by the heat generated from the other of the LEDs. Accordingly, the heat can be radiated effectively.

The reflector44(second reflector) is formed in an almost paraboloidal shape. The reflector44is formed using, for example, polycarbonate. This reflector44is positioned on the forward side of the lamp, with respect to the rear end surface of the reflector28(first reflector) and disposed below the LED16. The reflector44is formed as a reflecting surface which includes, as a reference surface, paraboloidal surface, which is formed by a parabola having a focal point near the LED16b. The surface of this reflector is deposited with aluminum. Thus, as shown inFIG. 6, the reflector reflects the light emitted from the LED16and irradiates the reflected light as almost parallel ray in the forward direction (irradiates as a diffused light in the horizontal direction). Further, the reflector44is formed as a one-piece structure with an extension50, for shielding the peripheries of the projector-type lamp unit14and the reflection-type lamp unit18so as not to be seen from the forward direction of the lamp. The reflector22is disposed on the rear surface side of the extension50. The extension50is formed in an almost cylindrical shape and the surface (the front face side) thereof is deposited with aluminum. Since the reflector44and the extension50are a one-piece structure, a step portion can be eliminated therebetween, and the appearance thereof at the time of the turning-off of the lamp can be attractive and further the number of parts can be reduced. Further, since the reflector44and the extension50are a one-piece structure, the front face side of the extension50and the reflecting surface of the reflector44can be simultaneously deposited with aluminum, whereby the deposition process can be simplified. That is, since the mirror finishing process such as the deposition process may be performed once with respect to the single member (the formed extension50and reflector44), the simplification of the processing procedure and the cost reduction can be further realized as compared with the related art in which the mirror finishing process is performed with respect to the two members separately.

The reflection-type lamp unit18according to the embodiment is disposed so as to almost contact the lower side of the projector-type lamp unit14. Therefore, the reflection-type lamp unit effectively utilizes a vacant area of the projector-type lamp unit14, which is not used for the transmission of the reflected light from the first reflecting surface28a. The effective use of this space can contribute to the miniaturization of the lamp. Further, since the projector-type lamp unit14and the reflection-type lamp unit18are fixed to the flat-plate shaped fixing portions220,222, which are formed by extending a part of the lamp body22, the relative positional accuracy can be improved and the light distribution accuracy of the lamp can also be improved.

In the reflection-type lamp unit18according to the embodiment, a light distribution pattern P2shown inFIG. 16, for example, can be formed by the light beam irradiated from the reflection-type lamp unit18. The front face cover20is disposed in the forward direction of the extension50and the lamp body22is disposed on the rear surface side thereof. An annular flange portion52is formed on the side surface of the extension50and an annular projection54is formed on the rear surface of the extension. The front face cover20is melted and adhered by ultrasonic bonding to the flange portion52, and the lamp body22is attached to the projection54.

The front face cover20(for example, polycarbonate) is formed in an almost cylindrical shape. The front face cover20is attached to the lamp body22so as to cover the front face of the lamp body22, and the one end side of the front face cover20is closed by an irradiation portion56of an almost disc shape which allows the light from the respective lamp units14,18to penetrate therethrough and thereby irradiate in the forward direction of the lamp. When the light from the respective lamp units14,18is irradiated in the forward direction of the lamp from the front face cover20, a predetermined light distribution pattern is formed. An annular adhesion surface20ais formed on the opening side end surface of the front face cover20. The adhesion surface20ais melted and adhered by using ultrasonic bonding to the flange portion52of the extension50.

As shown inFIGS. 3 to 5, the lamp body22is configured as a cylindrical body, with front and rear surfaces opened. The lamp body is formed by using a die cast of metal consisting mainly of aluminum. An annular seal groove58is formed at the opening end portion on the front face side of the lamp body22, and an attachment portion60is formed on the rear surface side thereof. The lamp body22is arranged in a manner that, at the time of the assembling thereof, the projection54of the extension50is attached within the seal groove58, and then the extension50and the lamp body22are mutually adhered by the sealing material filled in the seal groove58thereby to seal the space therebetween. Further, the lamp body22is arranged in a manner that the attachment portion60is coupled to the attachment portion62of the rear face cover24via screws.

Since the lamp body22in this embodiment is configured by metal, the heat resistance and the heat radiation property of the lamp body can be enhanced as compared with the lamp body22configured by resin, whereby the miniaturization of the lamp can be realized in the embodiment.

As shown inFIGS. 3 to 5, the rear face cover24is configured as a cylindrical body, in which the front surface is open and the rear surface is closed. The rear face cover is formed by using a die cast of metal consisting mainly of aluminum. The rear face cover24is attached to the lamp body22so as to cover the rear surface thereof. A concave portion64having a concave space is formed within the rear face cover24. A circuit board66for driving the light sources (LEDs12,16) is attached to the concave portion64in an almost vertical state. As shown inFIG. 4, a driving circuit for driving the LEDs12,16and a socket68(for feeding the LEDs12,16and the driving circuit, etc.) are mounted on the circuit board66. The periphery of the circuit board66is covered by an electromagnetic shielding cover70. A connector72is detachably attached to the socket68in which four pins are disposed in the horizontal direction. Four lead wires74,76,78,80are coupled to the connector72. The lead wires74,76are passed within a bushing84disposed beneath the lamp body22and coupled to a battery (not shown), whereby the driving circuit is supplied with electric power from the battery via the lead wires74,76and the connector72. The lead wire78is coupled to the one terminal of the connector35bof the attachment35attached to the fixing portion220. A lead wire82coupled to the other terminal of the connector35bis coupled to the one terminal of the connector35bof the attachment35attached to the fixing portion222. The lead wire80is coupled to the other terminal of the connector35b.

That is, the LEDs12,16are coupled in series with and supplied with electric power from the driving circuit via the lead wire78, the lead wire82and the lead wire80. In the case of supplying electric power to the driving circuit from the battery, since the bushing84is disposed beneath the lamp body22(beneath the lamp), it is possible to prevent such a phenomenon from occurring that water etc. enters into the lamp via the lead wires74,76etc. which are passed through the busing84in order to supply electric power to the circuit board66. Further, insulation resin96is filled in an area equal to or lower than a resin filling line95within the rear face cover24containing the circuit board66, whereby various kinds of parts (i.e., circuit parts) etc. constituting the driving circuit are fixed by the resin96.

As shown inFIG. 7AandFIG. 7B, for example, the driving circuit is configured by a switching regulator86. Taller parts among the various kinds of parts (i.e., circuit parts) constituting the driving circuit and the parts coupled to the driving circuit (for example, a transformer (e.g., transformer for a DC/DC converter)88, the socket68, etc.) are disposed collectively in the area on the rear side of the reflector44together with the connector72, the lead wires74,76,78,80etc. In contrast, shorter parts different from the tall parts, (for example, a transistor (MOSFET)90, a resistor92, a surface mount type capacitor94, etc.) are disposed mainly in the area on the rear side of the fixing portions220,222of the reflectors28,44.

That is, since the reflection-type lamp unit18has a shorter depth than the projector-type lamp unit14, the area on the rear surface side of the reflector44is vacant. Thus, the taller parts (the transformer88and the socket68) are collectively disposed in this vacant area, whereby the length of the rear face cover24in the axial direction thereof can be made short. As a result, the entire depth of the lamp can be made short, and so the miniaturization of the lamp can be realized.

Further, since the various kinds of parts (the transformer88, the transistor90, the resistor92, the surface mount type capacitor94etc.) constituting the driving circuit are fixed by the resin96, it is possible to prevent such a phenomenon from occurring that the various kinds of parts are damaged or degraded by the vibration. Further, the heat generated from the various kinds of parts is effectively radiated to the rear face cover24and the lamp body22via the resin96and so the reliability of the driving circuit can be enhanced.

Further, since the rear face cover24made of metal is integrally coupled to the lamp body22made of metal to form the electromagnetic shielding, the electromagnetic noise generated from the driving circuit can be suppressed from leaking outside. Furthermore, since the surface of the extension50coupled to the lamp body22is deposited with aluminum, the extension50also forms the electromagnetic shielding together with the rear face cover24made of metal and the lamp body22made of metal thereby to suppress the electromagnetic noise generated from the driving circuit from leaking outside.

In the case of using the vehicle lamp10according to the exemplary embodiment as a headlamp for a head light or an adverse weather lamp, a cowl cover100can be fixed to a vehicle body frame104via a rubber102. For example, as shown inFIG. 4, the vehicle lamp10is disposed on the rear surface side of the cowl cover100. When the driving circuit is driven in response to the operation of a driver thereby to lighten the LEDs12,16, the light emitted from the LED12is reflected by the first reflecting surface28aof the reflector28, then penetrates the projection lens32and the front face cover20and is irradiated to the forward direction of the lamp. On the other hand, the light emitted from the LED16is reflected by the reflector44, then penetrates the front face cover20and is irradiated to the forward direction of the lamp. In this case, light beam according to a predetermined light distribution pattern is irradiated in the forward direction of the lamp.

According to the exemplary embodiment, since the first reflecting surface28a, the second reflecting surface38aand the design portion40are configured as the reflection mirror unit42of a single part, the positional accuracy of the first reflecting surface28aand the second reflecting surface38acan be enhanced. Further, the light distribution efficiency can be improved and the number of the parts can be reduced.