Lighting device for vehicle and optical axis regulating device of lighting device for vehicle

An optical axis regulating device of a lighting device for a vehicle, which serves to vertically and transversely tilt a lamp unit supported on one fulcrum in a lamp housing formed by a lamp body having a concave portion and a transparent cover for covering an opening portion of the lamp body, includes a case, a slider movable in a longitudinal direction with respect to the case, an output portion rotatably supported on the slider and coupled to the lamp unit, a vertical regulating device for moving the slider in a longitudinal direction, and a transverse regulating device for rotating the output portion.

This application claims foreign priority from Japanese Patent Application No. 2006-306788 filed on Nov. 13, 2006, the entire contents of which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a novel lighting device for a vehicle and a novel optical axis regulating device of the lighting device for a vehicle. More specifically, the invention relates to a technique capable of independently carrying out a change in a vertical direction and a change in a transverse direction of an irradiating direction and reducing cost and size.

2. Related Art

Some lighting devices for a vehicle, for example, some headlamps for a car can change an irradiating direction into vertically and transversely optional directions.

In a lighting device for a vehicle described in Patent Document 1, a lamp unit is supported on a bracket, and the bracket is tilted transversely and vertically, More specifically, a transverse tilting actuator is driven to transversely tilt the bracket, and, furthermore, a vertical driving actuator is driven to vertically tilt the bracket.

In a lighting device for a vehicle described in Patent Document 2, a rotation in a transverse direction and a rotation in a vertical direction are carried out by one actuator.

Also, in a lighting device for a vehicle described in Patent Document 3, a rotation in a transverse direction and a rotation in a vertical direction are carried out by one actuator.[Patent Document 1] JP-A-2005-119463 Publication[Patent Document 2] JP-A-2005-186731 Publication[Patent Document 3] JP-A-2003-054310 Publication

In the lighting device for a vehicle described in the Patent Document 1, however, a transverse tilting actuator for transversely tilting a bracket and a vertical tilting actuator for vertically tilting the bracket are provided separately, and the number of components and required man-hours for assembly are large and a large number of harnesses for supplying power to each actuator and controlling the actuator are required. Consequently, cost is increased. Referring to left and right lighting devices, moreover, the actuator cannot be common. Also, in this respect, cost is increased.

In the lighting device for a vehicle described in the Patent Document 2, a coupling point to the bracket for a transverse tilt of the actuator is separated from a coupling point to the bracket for a vertical tilt, and mutual positional relationships are fixed. For this reason, there is no versatility and a bracket designed for the actuator is required. In addition, special actuators for left and right lighting devices are required respectively.

In the lighting device for a vehicle described in the Patent Document 3, one output portion is provided for the actuator and a common actuator to left and right lighting devices can be used. However, a tilt in the transverse direction and that in the vertical direction cannot be carried out independently at the same time.

SUMMARY OF THE INVENTION

In one or more embodiments of the present invention, a change in a vertical direction and a change in a transverse direction of an irradiating direction is enabled to be independently carried out at the same time and cost and size are reduced.

One or more embodiments of the present invention provides an optical axis regulating device of a lighting device for a vehicle, which serves to vertically and transversely tilt a lamp unit supported on one fulcrum in a lamp housing formed by a lamp body having a concave portion and a transparent cover for covering an opening portion of the lamp body, comprising a case, a slider movable in a longitudinal direction with respect to the case, an output portion rotatably supported on the slider and coupled to the lamp unit, vertical regulating means for moving the slider in the longitudinal direction, and transverse regulating means for rotating the output portion.

Moreover, one or more embodiments of the invention provides a lighting device for a vehicle, which serves to support one of an upper end and a lower end of the lamp unit, wherein the lamp unit comprises a light source and serves to forward irradiate light of the light source, wherein the optical axis regulating device is disposed in the lamp housing, wherein the other one of the upper end and the lower end of the lamp unit is coupled to the output portion.

In one or more embodiments of the invention, accordingly, it is possible to independently carry out a change in a vertical direction and a change in a transverse direction of an irradiating direction at the same time. Moreover, the lamp unit is supported tiltably in the vertical and transverse directions on one fulcrum in the lamp housing. Therefore, it is possible to decrease the number of components for supporting the lamp unit, thereby reducing cost and size.

One or more embodiments of invention provides an optical axis regulating device of a lighting device for a vehicle, which serves to vertically and transversely tilt a lamp unit supported on one fulcrum in a lamp housing formed by a lamp body and a transparent cover for covering an opening portion of the lamp body, comprising a case, a slider movable in a longitudinal direction with respect to the case, an output portion rotatably supported on the slider and coupled to the lamp unit, vertical regulating means for moving the slider in the longitudinal direction, and transverse regulating means for rotating the output portion.

In the optical axis regulating device of a lighting device for a vehicle according to one or more embodiments of the invention, accordingly, it is possible to independently carry out a change in a vertical direction and a change in a transverse direction of an irradiating direction at the same time. Moreover, the lamp unit is supported tiltably in the vertical and transverse directions on one fulcrum in the lamp housing. Therefore, it is possible to decrease the number of components for supporting the lamp unit, thereby reducing cost and size.

According to a second aspect of one or more embodiments of the invention, the transverse regulating means is a gear member supported on the slider rotatably around an axis which is orthogonal to a rotation axis of the output portion and mated with a gear portion formed in the output portion. Therefore, it is possible to independently change the irradiating direction of the lamp unit into the transverse direction. Moreover, it is possible to reduce a weight of the slider.

According to a third aspect of one or more embodiments of the invention, the vertical regulating means is a ball screw member extended in a longitudinal direction of the vehicle, rotatably supported on the case, and screwed into a screw hole formed on the slider. Therefore, it is possible to independently change the irradiating direction of the lamp unit into the vertical direction.

According to a fourth aspect of one or more embodiments of the invention, the ball screw member is moved in the longitudinal direction of the vehicle by means of a driving source to be driven by a manual and/or automatic operation from a remote place. Therefore, it is possible to independently change the irradiating direction of the lamp unit into the vertical direction.

One or more embodiments of invention provides a lighting device for a vehicle, which serves to support one of an upper end and a lower end of the lamp unit, wherein the lamp unit comprises a light source and serves to forward irradiate light of the light source, wherein the lamp unit is disposed in the lamp housing, and wherein the other one of the upper end and the lower end of the lamp unit is coupled to the output portion.

In a lighting device for a vehicle according to one or more embodiments of the invention, accordingly, it is possible to independently carry out a change in the vertical direction and a change in the transverse direction of the irradiating direction. Moreover, the lamp unit is supported tiltably in the vertical and transverse directions on one fulcrum in the lamp housing. Therefore, it is possible to decrease the number of components for supporting the lamp unit, thereby reducing cost and size.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The best mode for executing a lighting device for a vehicle and an optical axis regulating device of the lighting device for a vehicle according to the invention will be described below with reference to the drawings. In all embodiments which will be described below, embodiments of the invention are applied to a headlamp for a car and an optical axis regulating device of the headlamp for a car.

FIGS. 1 and 2show a first embodiment according to the invention.

A headlamp10for a car includes a lamp body110having a concave portion opened forward, and a front opening of the lamp body110is covered with a transparent cover120so that a lamp housing101is formed. A lamp unit130is supported in the lamp housing101tiltably in vertical and transverse directions. Furthermore, an actuator140is disposed as an optical axis regulating device for tilting the lamp unit130in the vertical and transverse directions in the lamp housing101.

The lamp unit130includes at least a reflector131, a projection lens132and a light source which is not shown, and serves to irradiate an illumination light forward. A body coupling portion133to be coupled to the lamp body110is formed on an upper end of the lamp unit130, and furthermore, an actuator coupling portion134to be coupled to the actuator140is formed on a lower end of the lamp unit130. In the embodiment, the body coupling portion133is formed as a sphere constituting a part of a ball joint portion. Moreover, the actuator coupling portion134is formed like a thick disk and has a lower surface provided with an opened coupling concave portion134a, and an engaging groove extended in a vertical direction (not shown) is formed on an inner peripheral surface of the coupling concave portion134a.

A lamp unit coupling portion112is formed on a lower surface of an upper surface portion111of the lamp body110. The lamp unit coupling portion112is formed as a ball receiving member constituting a part of the ball joint portion. The ball receiving member112has an opened spherical concave portion112aformed on a lower surface. The sphere (body coupling portion)133formed on the lamp unit130is internally fitted in the spherical concave portion112aso that a ball joint is formed therein. When the sphere (body coupling portion)133is rotated in the spherical concave portion112a, the lamp unit130can be tilted in the vertical and transverse directions.

The actuator140has an output portion142protruded upward from an upper surface of a case141. The output portion142is driven by a driving source constituted in the case141. The output portion142is formed as an output shaft and has an outer peripheral surface provided with engaging convex bars143,143, . . . extended in an axial direction. The output portion142is rotated around a rotating axis extended in an almost vertical direction according to a driving manner of a driving source constituted in the case141, and furthermore, is moved in a longitudinal direction by another driving manner of the driving source. In this specification, the longitudinal direction implies a longitudinal direction of a car into which the headlamp10for a car is loaded, and similarly, the transverse direction implies a transverse direction of the car.

The actuator140is fixed into an upper surface of a lower surface portion113of the lamp body110, and the output portion142is fitted in the coupling concave portion134aprovided on the lower end of the lamp unit130. The engaging convex bars143,143. . . formed on an outer peripheral surface of the output portion142are engaged with an engaging groove (not shown) formed on an inner peripheral surface of the coupling concave portion134aso that slip can be prevented from being generated in a rotating direction between the output portion142and the coupling concave portion134a.

In the headlamp10for a car, when the output portion142of the actuator140is rotated around a rotating axis extended in an almost vertical direction, the actuator coupling portion134fitting the output shaft142therein receives a rotating force around an axis extended in an almost vertical direction. Accordingly, the lamp unit130having the actuator coupling portion134formed thereon is rotated in the transverse direction. Consequently, an irradiating direction of the lamp unit130is changed in the transverse direction. When the output portion142of the actuator140is moved in the longitudinal direction, moreover, the actuator coupling portion134provided on the lower end is displaced in the longitudinal direction in a state in which a position in the longitudinal direction of the body coupling portion133provided on the upper end of the lamp unit130is fixed. Therefore, the lamp unit130is tilted in the vertical direction. Consequently, the irradiating direction of the lamp unit130is changed in the vertical direction.

Accordingly, the driving source of the actuator140is driven by a manual operation at a driver's seat or an automatic operation based on a result of detection obtained by detecting means for detecting a tilt of a car body through various sensors such as an axle sensor for detecting a height of an axle, for example. Consequently, it is possible to change the irradiating direction of the lamp unit130in the vertical and transverse directions at any time during running.

In a delivery from a factory or an automobile inspection, moreover, it is possible to carry out an aiming regulation, that is, an initial regulation of a light distribution by driving the actuator140while visually observing a pattern to be irradiated on a forward screen or automatically measuring an illuminance at each measuring point on the screen.

While the lamp unit130is coupled to the lamp body110by means of the ball joint in the embodiment, the lamp unit and the lamp body may be coupled to each other by means of a spring material such as a plate spring or a coil spring and the lamp unit may be tiltable in the vertical and transverse directions with respect to the lamp body by setting the coupling point as a fulcrum. Consequently, a coupling structure of the lamp unit to the lamp body can be simpler.

Next, the details of the actuator140will be described with reference toFIG. 2.

A slider144is supported in the case141of the actuator140movably in a longitudinal direction, and the output portion142is rotatably supported on the slider144. The output portion142is provided with sector gear portions142band142bwhich are protruded in a transverse direction.

Two motors145and145are disposed as driving sources in the case141, and worn gears146aand146aare formed integrally with transmission gears146and146to be rotated by driving gears145aand145aof the motors145and145.

Furthermore, cylindrical gears147and147are rotatably supported in the case141, and bevel gears147aand147aare formed on outer peripheral surfaces of the cylindrical gear147and147. Moreover, screw grooves147band147bare formed on central holes of the cylindrical gears147and147. The worm gears146aand146aof the transmission gears146and146are mated with the bevel gears147aand147aof the cylindrical gears147and147, when the motors145and145are rotated, accordingly, the cylindrical gears147and147are rotated.

Screw shaft portions148aand148aof transmitting members148and148having portions excluding front end portions as the screw shaft portions148aand148aare screwed into the screw grooves147band147bof the cylindrical gears147and147. When the cylindrical gears147and147are rotated, accordingly, the screw shaft portions148aand148aare fed by the screw grooves147band147b. Therefore, the transmitting members148and148are moved in a longitudinal direction.

The front ends of the transmitting members148and148are fixed to rack members149and149. Rack teeth149aand149aformed on the rack members149and149are mated with sector gear portions142aand142aof the output portion142.

In the actuator140, in the case in which two motors145and145are driven in opposite directions to each other when the output portion142is to be rotated, one of the rack members149is moved forward and the other rack member149is moved rearward. Therefore, the output portion142is rotated. When the two motors145and145are driven in the same direction, moreover, the two rack members149and149are moved in the same direction. Therefore, the output portion142is moved forward or rearward.

FIGS. 3 to 6show a second embodiment of the actuator.

An actuator20has an output portion220protruded upward from a case210, and the output portion220is rotated around an axis extended in an almost vertical direction and is provided movably in a longitudinal direction. A rotation driving mechanism230for rotating the output portion220around an axis extended in an almost vertical direction and a horizontal driving mechanism240for moving the output portion220in the longitudinal direction are constituted in the case210.

The output portion220takes an almost cylindrical shape and has a central hole221penetrating through a center. Moreover, engaging convex bars222,222, . . . extended in an axial direction are protruded from an almost upper half part of an outer peripheral surface of the output portion220. Moreover, a gear tooth is formed in an almost lower half part of the outer peripheral surface of the output portion220and is set to be a wheel gear portion231.

A slider241is provided in the case210movably in a longitudinal direction. The slider241is provided with a support shaft241aprotruded upward from an almost center and support walls241band241bextended in a longitudinal direction in a position placed slightly apart from the support shaft241ain a transverse direction. Moreover, a screw hole241cis formed to penetrate in a longitudinal direction. In the slider241, engaging convex pieces241dand241dprotruded from left and right side surfaces of the slider241are slidably engaged with guide grooves211and211formed on left and right internal side surfaces of the case210in an extension in the longitudinal direction. Consequently, the slider241is supported movably in the longitudinal direction in the case210.

The support shaft241aof the slider241is inserted through the central hole221so that the output portion220is rotatably supported on the slider241.

A worm gear232is rotatably supported between the support walls241band241bof the slider241, and the worm gear232is mated with the wheel gear portion231of the output portion220. When the worm gear232is rotated, accordingly, the output shaft220is rotated. The worm gear232is provided with a coupling portion232aprotruded outward from one of the support walls241band241b, and a coupling hole232bopened to an end face and having a rectangular section is formed on the coupling portion232a. The rotation driving mechanism230is constituted by the worm gear232and the wheel gear portion231formed on the output portion220.

A horizontal driving shaft242is provided to longitudinally penetrate through the case210, and a screw piece242aformed on an outer peripheral surface of the horizontal driving shaft242is screwed into the screw hole241cof the slider241. Accordingly, the screwhole241cof the slider241is fed through the screw piece242aof the horizontal driving shaft242by a rotation of the horizontal driving shaft242and the horizontal driving shaft242is moved in a longitudinal direction with respect to the case210so that the slider241is moved in the longitudinal direction with respect to the case210. Therefore, the output portion220supported on the slider241is moved in the longitudinal direction with respect to the case210. The horizontal driving mechanism240is constituted by the horizontal driving shaft242and the slider241. A compression coil spring241eis inserted between the slider241and an internal surface of a front end of the case210, and thus a looseness of the slider241can be prevented.

The horizontal driving shaft242is rotated and longitudinally moved as a driving shaft of a leveling driving portion30coupled to a rear end of the actuator20.

The leveling driving portion30is set into such a state that a case310thereof is coupled integrally with a rear end of the case210of the actuator20.

The screw piece242ais formed to be a screw shaft in a portion placed in a tip portion of the horizontal driving shaft242, that is, the case210of the actuator20, and a rear end is set to be a coupling portion and a coupling hole242bopened to the rear end and having an almost rectangular section is formed. Moreover, an intermediate portion242cprovided between the screw shaft portion and the rear end is set to be a supported portion taking a shape of a round bar.

The case310includes a cylindrical member320, a rotor330and a stator340which are disposed concentrically around the horizontal driving shaft242.

The cylindrical member320provided in the case310takes an almost wholly cylindrical shape and has a central hole321and a screw piece322is formed in a central part of an outer peripheral surface thereof, and furthermore, detent projections323and323protruded vertically are formed integrally with a rear end.

The horizontal driving shaft242is inserted into the central hole321of the cylindrical member320from a rear part thereof, and furthermore, washers242dand242dare externally fitted in a portion of the horizontal driving shaft242which is longitudinally protruded from the cylindrical member320so as to abut on the cylindrical member320. Consequently, the horizontal driving shaft242is supported rotatably with respect to the cylindrical member320and immovably in an axial direction thereof.

The rotor330also takes an almost wholly cylindrical shape, and has a screw groove332formed on a central hole331having an almost equal inside diameter to an outside diameter of the cylindrical member320and is rotatably supported on the case310. A plurality of permanent magnets (not shown) is attached as rotor magnets in an outer peripheral portion of the rotor330.

The stator340has a plurality of stator coils (not shown) corresponding to the rotor magnets and is fixedly disposed along an internal peripheral surface of the case310.

The cylindrical member320supporting the horizontal driving shaft242as described above is set into such a state that the cylindrical member320is inserted into the central hole331of the rotor330from a rear part thereof to screw the screw piece322into the screw groove332. The horizontal driving shaft242, the cylindrical member320and the rotor330are disposed in predetermined portions in the case310. At this time, the detent projections323and323of the cylindrical member320are slidably positioned in engaging concave portions311and311formed to be extended longitudinally in the case310.

In the horizontal driving shaft242, the screw piece242ais screwed into the screw hole241cof the slider241in the actuator20.

A tip portion243ahaving an almost rectangular section of a flexible wire243is fitted and fixed into the coupling hole242bof the horizontal driving shaft242. Moreover, a tip portion233ahaving an almost rectangular section of a flexible wire233is fitted and fixed into the coupling hole232bof the worm gear232in the rotation driving mechanism230. A rear end of the flexible wire243is coupled to an aiming operating portion40shown inFIG. 3. The aiming operating portion40is connected to an operating member410supported rotatably on a rear surface wall114of a lamp body, for example. A cross groove411is formed on a rear surface of the operating member410and is caused to face rearward from a facing hole114aformed on the rear surface wall114of the lamp body. Therefore, when a tip portion510of a plus driver50is engaged with the cross groove411of the operating member410to rotate the plus driver50, for example, the operating member410is rotated, and furthermore, the rotation of the operating member410is transmitted to the horizontal driving shaft242through the flexible wire243. Consequently, the slider241of the actuator20is moved in a longitudinal direction. More specifically, the output portion220is moved in the longitudinal direction. A rear end of the flexible wire233fitted and fixed into the coupling hole232bof the worm gear232in the rotation driving mechanism230is also connected to the same aiming operating portion (not shown) as the aiming operating portion40, when the flexible wire233is rotated, accordingly, the worm gear232is rotated so that the output shaft220is rotated.

In a leveling regulation, that is, an execution of a vertical change in an irradiating direction in the middle of running, moreover, when a stepping motor constituted by the rotor330and the stator340is operated, that is, a driving current is supplied to a stator coil (not shown) of the stator340so that the rotor330is rotated, the cylindrical member320screwed there into is prevented from being rotated by the engagement of the detent projections323and323and the engaging concave portions311and311and is moved forward or rearward corresponding to a rotating direction of the rotor330. The horizontal driving shaft242integrated with the cylindrical member320is also moved integrally with the cylindrical member320in a longitudinal direction. Accordingly, the slider241of the actuator20is moved in the longitudinal direction.

When the output portion220of the actuator20is coupled to an actuator coupling portion134of a lamp unit130, therefore, the lamp unit130is tilted in a transverse direction by the driving operation of the rotation driving mechanism230and the lamp unit130is tilted in a vertical direction by the driving operation of the horizontal driving mechanism240. By the driving operation of the leveling driving portion30, similarly, the lamp unit130is tilted in the vertical direction.

FIG. 7shows a third embodiment of the actuator.

An actuator60according to the third embodiment is different from the actuator20according to the second embodiment in that a leveling driving portion30is not provided. More specifically, in the actuator60, a horizontal driving shaft610and a support structure thereof are different from the horizontal driving shaft242of the actuator20and the other portions are the same as in the actuator20. Accordingly, only the difference will be described in detail, and the other portions have the same reference numerals as those of the actuator and description will be omitted.

The horizontal driving shaft610is constituted by a screw shaft portion611having a screw piece formed on an outer peripheral surface and a coupling portion612formed integrally with a rear end of the screw shaft portion611. The coupling portion612is provided with a coupling hole612ahaving a rectangular section. The horizontal driving shaft610is supported on a case210in such a manner that it can be rotated in a direction extended in a longitudinal direction and a movement in the longitudinal direction is disabled. The coupling hole612aof the coupling portion612is caused to face rearward and a tip portion613ahaving a rectangular section in a flexible wire613to be rotated from an outside is fitted and fixed into the coupling hole612a.

Accordingly, when the flexible wire613is operated by an operating portion such as the aiming operating portion40and is thus rotated from an outside, for example, the horizontal driving shaft610coupled thereto is rotated so that a slider241is moved in the longitudinal direction along the horizontal driving shaft610and an output shaft220supported on the slider241is moved in the longitudinal direction. By the movement in the longitudinal direction of the output shaft220, a lamp unit is tilted vertically.

Although there has been described the example in which the horizontal driving shaft and worm gear and the aiming operating portion are linked to each other through the flexible wire in the second and third embodiments, it is also possible to employ a structure in which a coupling portion of the horizontal driving shaft and the worm gear is extended straight and can be directly operated by a jig such as a plus driver or can be operated through an orthogonal transforming gear in the case in which the aiming operating portion can be disposed close to the actuator.

While description has been made in connection with an exemplary embodiment of the present invention, it will be obvious to those skilled in the art that various changes and modification may be made therein without departing from the present invention. It is aimed, therefore, to cover in the appended claims all such changes and modifications falling within the true spirit and scope of the present invention.

DESCRIPTION OF THE REFERENCE NUMERALS AND SIGNS