Dual light path forming type projection optical system and head lamp and vehicle to which the same optical system is applied

A dual light path forming type projection optical system may include a reflector allowing light generated from a light source to be formed into a lower reflecting light reflected to an upward path directing upward and an upper reflecting light reflected to a downward path directing downward, a prism lens allowing the upper reflecting light to be emitted as a prism low beam in which the downward path is changed into the upward path and allowing the prism low beam to be changed into a prism high beam by changing an incident angle of the upper reflecting light, and an aspheric lens for generating a low beam by allowing the prism low beam to be added to the lower reflecting light and generating a high beam by allowing the prism high beam to be added to the lower reflecting light.

CROSS-REFERENCE(S) TO RELATED APPLICATIONS

The present application claims priority to Korean Patent Application No. 10-2016-0058828, filed on May 13, 2016, the entire contents of which is incorporated herein for all purposes by this reference.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relate to a projection headlamp, and more particularly to a dual light path forming type projection optical system that can use light which has been thrown away by being blocked by a shield as well as a projection headlamp and a vehicle to which the projection optical system is applied.

Description of Related Art

Typically, a vehicle headlamp uses a light source installed in the center of a hemispherical shaped reflector having thin thickness as a light source and it is configured in such a manner that a direction of irradiating the light source is regulated to either a high beam condition or a low beam condition by manipulation of a switch by a driver.

A projection headlamp among such headlamps adopts a projection optical system in which the lamp itself is constituted as a unit.

As an example, the projection headlamp includes a light source, a reflector forming an elliptical reflecting surface on which a filament of the light source is formed as a first focus and the light from the light source is reflected, a projection holder forming a second focus while blocking a portion of the light by a shield, an aspheric lens allowing the light to be transmitted therethrough, and a lamp lens (or outer lens) allowing the light to be transmitted therethrough and then illuminate a road surface. In this case, a group of the light source, the reflector, the projection holder and the aspherical lens is referred to as a projection optical system. In particular, the shield that is a cut-off component for blocking the light source of the upper portion of the reflector is a prerequisite component for meeting laws and regulations requiring that the light source shall be irradiated within a low beam area.

Therefore, according to the projection headlamp, the light generated in the light source located in the first focal plane of the elliptical reflecting surface of the reflector is reflected on the elliptical reflecting surface, the reflected light passes over the second focal point and is transmitted through the aspheric lens, and then the light transmitted through the aspheric lens is irradiated to the front road surface through the lamp lens However, the projection optical system applied to the projection headlamp is implemented in a low luminous efficiency and hence a lot of light is not used.

Low luminous efficiency can be seen from the following calculation formula of efficiency of the projection optical system.
Efficiency of projection optical system (%)=transmittance of lamp lens×transmittance of aspheric lens×efficiency of shield×reflectance of reflector×(effective solid angle of reflector/effective solid angle of light source)

Where the transmittance of lens indicates a transmission factor, the efficiency of shield indicates a blocking factor, and the reflectance of mirror indicates a reflecting factor.

For example, if the effective solid angle of the light source is 12.56 steradian (sr), the effective solid angle of the reflector is 9.93 steradian, the reflectance of the reflector is 85%, the efficiency of the shield is 60%, the transmittance of the aspheric lens is 85%, and the transmittance of the lamp lens 88%, then the efficiency (%) of the projection optical system is as follows:
0.3016=0.88×0.85×0.6×0.85×(9.93/12.56)

Where the symbol “×” is the multiplication sign.

It can be seen from this that in order to improve the low luminous efficiency of 30.2%, all or each of the transmission factor, the blocking factor and the reflecting factor must be improved. However, improvement of the transmittance and the reflectance is very difficult technically. Furthermore, since the shield is required to block the upper reflecting light which is reflected on the reflector and directs downward in order to meet the related laws and regulations, improvement of the shield by a manner that the upper reflecting light is not blocked is inevitably difficult due to the restriction by the related laws and regulations.

As a result, in a vehicle in which a projection optical system having a low luminous efficiency of 30.2% is applied as a projection headlamp, quantity of light of the low beam is inevitably low and further the low beam having such low quantity of light makes it difficult to meet the requirements of the driver driving at night who wishes to secure a brighter front field of view.

BRIEF SUMMARY

Various aspects of the present invention are directed to providing a dual light path forming type projection optical system that can increase luminance efficiency of the projection optical system significantly without any necessary to improve a transmission factor, a blocking factor and a reflection factor, which are difficult to improve, by utilizing light reflected on upper and lower portions of a reflector in irradiating light beam through changeover of light path by a polarization angle prism lens, and that can provide the front field of view at night more brightly by a low beam and a high beam both having high quantity of light formed by adding the light reflected on the upper portion of the reflector, which has been blocked and hence not been used when a shield is applied, to quantity of light of the low beam and the high beam. In addition, it is to provide a headlamp and a vehicle to which the projection optical system is applied.

In accordance with one aspect of the present invention for obtaining the object as mentioned above, various aspects of the present invention are directed to providing a dual light path forming type projection optical system including: a reflector allowing light generated from a light source to be formed into a lower reflecting light reflected to an upward path directing upward and an upper reflecting light reflected to a downward path directing downward simultaneously; a prism lens allowing the upper reflecting light to be emitted as a prism low beam in which the downward path is changed into the upward path and allowing the prism low beam to be changed into a prism high beam by changing an incident angle of the upper reflecting light; and an aspheric lens for generating a low beam by allowing the prism low beam to be added to the lower reflecting light and generating a high beam by allowing the prism high beam to be added to the lower reflecting light.

In an exemplary embodiment, the path of the lower reflecting light is formed above the path of the prism low beam and the path of the prism high beam and rotation of the prism lens causes a change of the incident angle.

In an exemplary embodiment, the prism lens is subdivided into a light source incident surface forming an incident angle, a light source output surface forming an output angle, a light source reflecting surface opposite to the light source output surface, and a prism forming surface opposite to the light source incident surface, wherein the light source incident surface is orthogonal to the light source output surface.

In an exemplary embodiment, a compensating lens is positioned beside the aspheric lens between the aspheric lens and the prism lens in a position deviated from the path of the lower reflecting light directing to the aspheric lens, wherein the compensating lens compensates each of the prism low beam and the prism high beam.

In an exemplary embodiment, the reflector is formed in a funnel shape forming a reflecting surface for reflecting each of the lower reflecting light and the upper reflecting light, wherein the reflecting surface is formed in an elliptical shape.

In an exemplary embodiment, the reflector and the aspheric lens are connected by a projection holder, the prism lens is positioned in the inside space of the projection holder, a sitting rim is coupled with the projection holder, and the sitting rim maintains the assembled condition of the projection holder and the aspheric lens.

In accordance with another aspect of the present invention for obtaining the object as mentioned above, various aspects of the present invention are directed to providing a projection headlamp including: a projection optical system including a reflector allowing a path of light generated from a light source to be formed into a lower reflecting light and an upper reflecting light simultaneously, a prism lens allowing the upper reflecting light to be changed into a prism low beam and a prism high beam by changing an incident angle, an aspheric lens for generating a low beam in which the prism low beam is added to the lower reflecting light and generating a high beam in which the prism high beam is added to the lower reflecting light, a projection holder for connecting the reflector and the aspheric lens while allowing the prism lens to be positioned in the inside space thereof, a compensating lens positioned beside the aspheric lens to compensate each of the prism low beam and the prism high beam, and a sitting rim coupled with the projection holder in which the aspheric lens is positioned; a lamp lens for irradiating forward each of the low beam and the high beam emitted from the projection optical system; and a lamp housing to which the lamp lens is coupled.

In an exemplary embodiment, the projection headlamp further includes a terminal connector provided in the lamp housing to allow the projection optical system to be supplied with power and allow control signal to be input and a lens actuator provided in the lamp housing to select one of the low beam and the high beam of the projection optical system.

In an exemplary embodiment, the projection headlamp further includes an adaptive driving beam (ADB) shield for forming a shadow zone in the high beam of the projection optical system.

Furthermore, in accordance with still another aspect of the present invention for obtaining the object as mentioned above, various aspects of the present invention are directed to providing the vehicle including a projection headlamp including a projection optical system, wherein the projection optical system includes a reflector allowing a path of light generated from a bulb to be formed into a lower reflecting light and an upper reflecting light simultaneously, a prism lens allowing the upper reflecting light to be changed into a prism low beam and a prism high beam by changing an incident angle, an aspheric lens for generating a low beam in which the prism low beam is added to the lower reflecting light and generating a high beam in which the prism high beam is added to the lower reflecting light, a projection holder for connecting the reflector and the aspheric lens while allowing the prism lens to be positioned in the inside space thereof, a compensating lens positioned beside the aspheric lens to compensate each of the prism low beam and the prism high beam, and a sitting rim coupled with the projection holder in which the aspheric lens is positioned, and wherein the projection headlamp is applied as a headlight on both left and right sides of the vehicle.

In an exemplary embodiment, the projection headlamp further includes an adaptive driving beam (ADB) shield wherein the ADB shield forms a shadow zone in the high beam of the projection optical system.

According to this projection headlamp of the present invention, the projection optical system forms a dual light path in the inside thereof so that the following advantages and effects are realized.

First, as the light path can be changed by the prism lens, a rate of utilization of light source is increased significantly with the same effect as when a shield is applied while meeting laws and regulations related to projection headlamps. Second, as the light reflected on the upper portion of a reflector, which has been thrown away when a shield is applied, is added to quantity of light of the low beam and the high beam by the action of the prism, so that luminance efficiency of the projection headlamp is greatly improved. Third, by application of the prism lens, it is possible to improve performance of a projection headlamp without any difficulty in technical approaches to improve including a transmission factor, a blocking factor and a reflection factor. Fourth, as the light path of the prism lens is added to the conventional low beam path and forms a dual light path, performance of the low beam is enhanced up to approximately 45% compared to the conventional low beam. Fifth, switching from a high beam to a low beam and vice versa can be made only by changing a light path of the prism lens, expanding bifunctional function. Sixth, chrominance separation and compensation of a predetermined undesired angle of the light from the prism can be easily made by associating the compensating lens with the prism lens. Seventh, it is also possible to cut off adaptive driving beam (ADB) function by associating the prism shield having ADB function with the prism lens.

DETAILED DESCRIPTION

Referring toFIG. 1, a projection optical system9includes a light source10, a reflector20, a projection holder30, an aspheric lens50, a sitting rim60, a prism lens70, and a compensating lens80.

The light source10is a light source for generating light, which may include a filament, and it is coupled with the reflector20. The light source10is coupled from the rear side of the reflector20and positioned in the center of the reflector, while the projection holder30is coupled in front of the reflector. The projection holder30connects the reflector20and the aspheric lens50, and acts as a path through which light reflected from the reflector20moves. The aspheric lens50allows the lower reflecting light reflected on a lower reflecting surface21aof the reflector20to transmit therethrough. The sitting rim60includes an annular ring and keeps the engaged state between the projection holder30and the aspheric lens50.

The prism lens70is subdivided into four surfaces, i.e., a light source incident surface71, a light source output surface73, a light source reflecting surface75and a prism forming surface77. A path of the light passing through the prism lens70forms refraction of an incident path by transmission of the light source incident surface71, turnover of a reflecting path by reflection of the light reflecting surface75and refraction of an output path by transmission of the light source output surface73, wherein the light emitting from the light source output surface73by refraction of the output path is turned by 90 degrees with respect to an incident angle.

The compensating lens80performs chrominance separation of the light output from the prism lens70and compensation of an angle of undesired light at a position before the step where the prism lens70transfers the upper reflecting light reflected on an upper reflecting surface21bof the reflector20to the aspheric lens50.

Therefore, the projection optical system9forms a dual light path where the upper reflecting light which has been blocked by a shield and not been utilized can be mixed with the lower reflecting light by the action of the prism lens70.

As an example, when the projection optical system9is operated, the light source10serving as a light source generates light. The light generated is reflected on lower and upper portions of the reflector20respectively, wherein the lower reflecting light is reflected in an upward direction and then projected directly to the aspheric lens50so that it is formed as a low beam path, while the upper reflecting light is reflected in a downward direction and turned to an upward direction by the prism lens70and then projected to the aspheric lens50through the compensating lens80so that it is formed as a prism path. The light of the low beam path and the light of the prism path are transmitted through the aspheric lens50and irradiated in front of the aspheric lens50.

The projection optical system9can change an output angle of the upper reflecting light by about reflector20respectively, wherein the lower reflecting light is reflected in an upward direction and then projects. The prism low beam allows quantity of light of the low beam to increase, while the prism high beam allows the low beam to be formed as the high beam.

Referring toFIG. 2, the reflector20is formed in a funnel shape and includes a reflecting surface21, a bulb hole22and front and rear reflector flanges23-1,23-2. The reflecting surface21is formed in an elliptical shape surrounding a filament of the light source10positioned in the center thereof and divided into a lower reflecting surface21awhich is a lower space below the filament and an upper reflecting surface21bwhich is an upper space above the filament. The bulb hole22is formed to pierce the reflecting surface21such that the filament of the bulb10is fitted therein. The front and rear reflector flanges23-1,23-2are formed on both end portions of the reflecting surface21, wherein the front reflector flange23-1is coupled with the projection holder30while the rear reflector flange23-2is coupled with a housing of the projection headlamp.

Referring toFIG. 3, the prism lens70is a constant polarization angle type prism lens that maintains a polarization angle at 90° such that an incident angle and an output angle are orthogonal with each other (at right angles to each other) by subdividing it into four surfaces, i.e., a light source incident surface71, a light source output surface73, a light source reflecting surface75and a prism forming surface77. For example, an angle of a vertex A between the light source incident surface71and the light source output surface73is 90 degrees, an angle of a vertex B between the light source incident surface71and the light reflecting surface75is 75 degrees, an angle of a vertex C between the light source reflecting surface75and the prism forming surface77is 135 degrees, and an angle of a vertex D between the prism forming surface77and the light source output surface73is 60 degrees. Therefore, the prism lens70is subdivided into a triangle formed by the light source incident surface71and the light source output surface73and a triangle formed by the light source output surface73and the prism forming surface77.

Referring toFIG. 4, a projection optical system9includes external parts including a reflector20, a projection holder30, an aspheric lens50and a sitting rim60and inside parts including a bulb10, a prism lens70and a compensating lens80.

The projection holder30includes a rear holder flange33-2and a front holder protrusions33-3, wherein it is screw (or bolt) fastened to the front reflector flange23-1of the reflector20by the rear holder flange33-2and the front holder protrusions33-3are coupled with assembly holes60-1of the sitting rim60so that the front portion to which the aspheric lens50is fitted is tightened. As a result, the assembled condition of the reflector20and the aspheric lens50in the projection optical system9is maintained firmly by the action of the projection holder30.

The light source10is strongly bound to the reflector20through the light bulb hole22of the reflector20so that it is prevented from being broken away from the assembled condition. The prism lens70is mounted to be rotatable by approximately 30 degrees, utilizing the inside space structure of the projection holder30and the compensating lens80is erected vertically to be abutted against the lower portion of the aspheric lens50, utilizing the inside space structure of the projection holder30. In the instant case, a section where the compensating lens80is overlapped with the aspheric lens50is restricted to lay on the lower side of the path through which the lower reflecting light is projected to the aspheric lens50.

Referring toFIG. 5, a projection headlamp1includes a projection optical system9including a lamp housing3, a lamp lens5, an adjusting bolt6, a terminal connector7and a prism lens70as its major components, forming a dual light path by the prism lens70.

The lamp housing3forms an inside structure in which the projection optical system9is mounted and includes an outside shape tailored to a mounting structure of a vehicle in which the projection headlamp1is mounted as a headlamp. The lamp lens5is coupled with the front face of the lamp housing3, and irradiates light emitted from the projection optical system9toward the front of the vehicle to secure the driver's front field of view. The adjusting bolt6is provided in the lamp housing3to adjust an angle and the like for mounting the projection optical system9to the vehicle. The terminal connector7is connected to an electrical circuit for supplying power when the projection headlamp1operates and changeover between the high and the low beam.

The projection optical system9includes a light source10, a reflector20, a projection holder30, an aspheric lens50, a prism lens70, a lens actuator70-1and a compensating lens80. Therefore, the projection optical system9is the same as the projection optical system9described throughFIGS. 1 to 4.

However, there are differences in that the prism lens70is configured together with the lens actuator70-1mounted by utilizing the structure of the lamp housing3and the projection holder30has a structure altered such that the lens actuator70-1is associated with the prism lens70. As a result, when the lens actuator70-1rotates the prism lens70by approximately 30°, the prism path can be divided into a prism low beam and a prism high beam. The prism low beam forms a low beam by being combined with the low beam in the low beam path, while the prism high beam forms a high beam by being combined with the low beam in the low beam path. As an example, the lens actuator70-1may be a step motor or a solenoid valve.

On the other hand,FIGS. 6 and 7show a low beam operating state of the projection headlamp1.

Referring toFIG. 6, when the projection headlamp1is operated by manipulation of a switch by the driver, a low beam is set as default. That is, a switch operation signal by the driver is transferred through the terminal connector7to turn on the light source10while the prism lens70is held in its initial position as the lens actuator70-1is held in its initial state. At this time, the initial position of the prism lens70also means zero degree which is compared with 30 degrees that is an angle where the high beam occurs.

The light generated by the light source10as a light source is reflected as the lower reflecting light on the lower reflecting surface21aof the reflector20and bent upward and at the same time it is also reflected as the upper reflecting light on the upper reflecting surface21bof the reflector20and bent downward. Then, the lower reflecting light is projected directly to the aspheric lens50and transmitted through the aspheric lens50as a low beam LB. At the same time, the upper reflecting light is projected to the compensating lens80by changeover of its path by the prism lens70. The light transmitted through the compensating lens80is projected to the aspheric lens50after the light emitted from the prism lens70is subjected to chrominance separation and compensation of a predetermined undesired angle, and then transmitted through the aspheric lens50as a prism low beam PLB. Then, the low beam LB and the prism low beam PLB which are transmitted through the aspheric lens50are transmitted through the lamp lens5and irradiated forward, generating a low beam.

Referring toFIG. 7, it can be seen that a low beam200of high quantity of light in which the low beam LB and the prism low beam PLB are combined with each other is irradiated with more light energy to the front of the vehicle100so that the front field of view becomes brighter and at the same time extension of light energy to the side of the vehicle100occurs so that brightness of the side extended field of view200-1is also further improved. This result has been experimentally demonstrated.

On the other hand,FIGS. 8 and 9show a high beam operating state of the projection headlamp1. Hereinafter, it is assumed that the high beam is switched from the low beam state.

Referring toFIG. 8, a switch operation signal by the driver is transferred through the terminal connector7and hence the lens actuator70-1operates to rotate the prism lens70by approximately 30 degrees, so that the prism lens70is changed to a position rotated by 30 degrees from its initial position. As a result, as an incident angle of the upper reflecting light relative to the prism lens70is also changed by 30 degrees but a polarization angle of 90 degrees is still maintained, an output angle of the prism lens70goes down to the bottom by 30 degrees compared to 0 degree.

the light generated by the light source10as a light source is reflected as the lower reflecting light on the lower reflecting surface21aof the reflector20and bent upward and at the same time it is also reflected as the upper reflecting light on the upper reflecting surface21bof the reflector20and bent downward. Then, the lower reflecting light is projected directly to the aspheric lens50and transmitted through the aspheric lens50as a low beam LB. At the same time, the upper reflecting light enters into the prism lens70at the incident angle of the high beam bent by 30 degree compared to the incident angle of the low beam and hence the path of the output angle of the high beam is changed to the upper side 30 degrees lower than the output angle of the low beam so that the upper reflecting light is projected to the lower portion of the compensating lens80. Then, the light transmitted through the compensating lens80is projected to the aspheric lens50after the light emitted from the prism lens70is subjected to chrominance separation and compensation of a predetermined undesired angle, and then transmitted through the aspheric lens50as a prism high beam PHB. Then, the low beam LB and the prism high beam PHB which are transmitted through the aspheric lens50are transmitted through the lamp lens5and irradiated forward, generating a high beam.

Referring toFIG. 9, it can be seen that a high beam300of high quantity of light in which the low beam LB and the prism high beam PHB are combined with each other is irradiated with more light energy to the front of the vehicle100so that the front field of view becomes brighter and performance of securing the front field of view is also further improved. This result has been experimentally demonstrated.

FIG. 10, andFIG. 11show an example that the projection optical system9to which an adaptive driving beam (ADB) shield40-1is applied implements an ADB mode. In the instant case, the ADB mode means operation of the headlamp, by which a shadow zone is formed during activation of the high beam.

Referring toFIG. 10, the projection optical system9includes the ADB shield40-1applied to the projection holder30. The ADB shield40-1is positioned to be associated with the prism lens70within the inside space of the projection holder30and the outer appearance of the ADB shield40-1is formed in a peanut shape by changing its inside angle and shape such that a shadow zone forming surface40-1A is formed, so that the shadow zone is formed when the ADB mode is operated. The ADB shield40-1is linked to the lens actuator70-1which rotates the prism lens (70) to move, or otherwise a separate ADB actuator or ADB solenoid valve is applied to the ADB shield such that operation of the ADB shield is controlled by manipulation of a switch.

Therefore, similarly to the projection optical system9described throughFIGS. 1 to 9except for the ADB shield40-1, this projection optical system9also includes a bulb10, a reflector20, a projection holder30, an aspheric lens50, a sitting rim60, a prism lens70, and a compensating lens80.

Referring toFIG. 11, the driver of the vehicle100equipped with the projection headlamp1switches to the ADB mode when he/she finds an upcoming vehicle100-1during running the vehicle with the front field of view secured by the high beam300of high quantity of light. Then, the shadow zone forming surface40-1A of the ADB shield40-1blocks a portion of the light being projected to the aspheric lens50so that the high beam300of high quantity of light is changed to an ADB high beam400in which the shadow zone400-1is formed. As a result, the high beam300of high quantity of light of the vehicle100does not affect the upcoming vehicle100-1. The driver of the upcoming vehicle100-1does not suffer inconvenience due to dazzling light.

As described above, the projection headlamp according to the present exemplary embodiment includes a dual light path forming type projection optical system9including a reflector20on which light generated from a bulb10is formed into a lower reflecting light reflected to an upward path directing upward and an upper reflecting light reflected to a downward path directing downward simultaneously, a prism lens70through which the upper reflecting light is emitted as a prism low beam in which the downward path is changed into the upward path, and an aspheric lens50for irradiating a low beam by adding the prism low beam to the lower reflecting light, wherein it is applied to a headlamp for a vehicle, and enhances efficiency of using light energy by allowing the prism lens70to utilize as quantity of light for a low beam and a high beam the light that may not be utilized due to blocking out by a shield during operation in the prior art and, increases luminance efficiency of the projection headlamp1significantly without any necessary to improve a transmission factor, a blocking factor and a reflection factor which are difficult to improve.