Headlamp structure

A headlamp structure has a contoured reflector panel with a forward-facing surface and a reflex supporting portion. The forward-facing surface has a plurality of reflector surface portions. The reflex supporting portion extends forward from an inboard side inboard of the reflector surface portions. A passive reflector is attached to the reflex supporting portion with a reflector surface that faces an outboard direction relative to the forward-facing surface. Each of the plurality of reflector surface portions is shaped and configured to reflect light from a corresponding one of a plurality of light emitting elements and aim the reflected light to project in a forward direction parallel to the reflector surface of the passive reflector. The reflector surface of the passive reflector is configured such that at least light approaching the contoured reflector panel from outboard of an outboard side of the contoured reflector panel is reflected back in the outboard direction.

BACKGROUND

Field of the Invention

The present invention generally relates to a vehicle headlamp structure that includes a contoured reflector. More specifically, the present invention relates to a contoured reflector of a headlamp structure that aims light emitted from the headlamp structure to shine in a forward direction of a vehicle, the contoured reflector also having a passive reflector fixedly attached to the contoured reflector that receives light shining from an outboard side of the vehicle (and the headlamp structure) and reflects at least a portion of that light in the outboard direction outboard of the headlamp structure.

Background Information

The S.A.E. (Society of Automotive Engineers) defines a reflex reflector as a device which is used on a vehicle to give an indication to an approaching driver by reflected light from the lamps on the approaching vehicle.

Reflex reflectors are typically used on bicycles and automotive vehicles. Reflex reflectors are not mirrors per se. Reflex reflectors are typically optic elements designed to take light aimed at the reflex reflector and return that light back in directions proximate the entrance angle of the light but with significantly reduced brightness, and with a small degree of angular displacement and/or diffusion.

SUMMARY

One object of the present disclosure is to provide a headlamp structure with a contoured reflector that aims headlamp light in a forward direction and includes a reflex supporting portion that extends in a forward direction approximately parallel to the forward direction, where a reflex reflector mounted to the reflex supporting portion reflects light in a vehicle outboard direction, the reflux supporting portion being integrally formed with the contoured reflector as a single, monolithic element.

In view of the state of the known technology, one aspect of the present disclosure is to provide a headlamp structure with a contoured reflector panel, a passive reflector and a plurality of light emitting elements. The contoured reflector panel has an inboard side, an outboard side, and a top side, a forward-facing surface and a reflex supporting portion. The forward-facing surface has a plurality of reflector surface portions that extend downwardly from the top side of the contoured reflector panel. The reflex supporting portion extends forward from the inboard side inboard of the plurality of reflector surface portions. The passive reflector is fixedly attached to the reflex supporting portion with a reflector surface of the passive reflector facing an outboard direction. The plurality of light emitting elements are located proximate respective upper ends of corresponding ones of the plurality of reflector surface portions. The plurality of light emitting elements emit light to the corresponding one of the plurality of reflector surface portions, with each of the plurality of reflector surface portions being shaped and configured to reflect light from the corresponding one of the plurality of light emitting elements and aim the reflected light to project in a forward direction parallel to the reflector surface of the passive reflector. The reflector surface of the passive reflector is configured and oriented such that at least a portion of light approaching the passive reflector from outboard of the outboard side of the contoured reflector panel is reflected back in the outboard direction.

DETAILED DESCRIPTION OF EMBODIMENTS

Referring initially toFIG. 1, a vehicle10with headlamp structures12is illustrated in accordance with a first embodiment.

The front end of the vehicle10is depicted inFIG. 1. The vehicle10defines a plurality of conventional directions, such as a center line CL, outboard directions Do (relative to the center line CL) and inboard directions DI(relative to the center line CL).

The vehicle10has a vehicle body structure14with a driver's side16and a passenger's side18. There are two headlamp structures12, each basically being the same with identical features, except that the headlamp structures12are symmetrically arranged with respect to one another, being mirror images of one another. One of the headlamp structures12is installed to the front end of the vehicle10at the driver's side16thereof, with the other of the headlamp structures12being installed to the front end of the vehicle10at the passenger's side18thereof, as shown inFIG. 1.

One of the headlamp structures12is depicted inFIGS. 2-6removed from the vehicle10. Since the two headlamp structures12are identical (but mirror images of one another), only one headlamp structure12is described herein, but applies equally to both headlamp structures12.

FIG. 2is a perspective view of the headlamp structure12shown removed from the driver's side16of the vehicle body structure14of the vehicle10.FIG. 2shows the headlamp structure12with a lens22attached to a housing24.FIGS. 2, 4 and 5show the headlamp structure12with the lens22fixedly attached to the housing24. InFIGS. 3 and 6the headlamp structure12is shown with the lens22removed and omitted for the sake of clarity and simplicity.

As shown inFIGS. 2, 4 and 5, the lens22includes a low beam lamp area LB, a high beam lamp area HB, a turn signal lamp area TL, a first daytime lamp area D1and a second daytime lamp area D2. InFIGS. 3, 6, 8 and 9and the description below, the turn signal lamp area TL, the first daytime lamp area D1and the second daytime lamp area D2are all omitted for the sake of brevity.

As shown inFIG. 3, is an exploded perspective view that shows the basic elements of the headlamp structure12, except the lens22and elements that define a turn signal lamp of the turn signal lamp area TL, a first daytime lamp of the first daytime lamp area D1and a second daytime lamp of the second daytime lamp area D2, which are omitted for the sake of brevity.

The headlamp structure12basically includes the housing24, an aiming bracket26, a circuit board28, a contoured reflector panel30and a reflex reflector32. The aiming bracket26, the circuit board28and the contoured reflector panel30are all installed within the housing24, and, are then covered and sealed within the housing24by the attachment of the lens22to the housing24.

As show inFIG. 2, the headlamp structure12includes at least first, second, third and fourth attachment flanges34,36,38and40that are used to secure the headlamp structure12to the vehicle body structure14. The lens22, the first attachment flange34and the fourth attachment flange40can be formed or molded together as a single element. Alternatively, the first attachment flange34and the fourth attachment flange40can be part of the housing24. The first attachment flange34extends in the inboard direction DIfrom the lens22(and/or the housing24), as shown inFIG. 2, and attaches an inboard side42of the headlamp structure12to the vehicle body structure14in a conventional manner. In the depicted exemplary embodiment, as shown inFIG. 2, an outboard side44of the headlamp structure12does not have any flanges. The fourth attachment flange40extends along a forward portion of a bottom side48of the lens22. The fourth attachment flange40includes a series of surfaces that can engage and/or snap-fit to corresponding portions of a front fender or grill (not shown) at the front end of the vehicle body structure14, in a conventional manner.

The second attachment flange36and the third attachment flange38are both part of the housing24. More specifically, the second attachment flange36and the third attachment flange38are molded simultaneously with the housing24are made of the same material as the housing, such as a plastic, polymer or resin material, or any other suitable moldable material. The second attachment flange36and the third attachment flange38are formed along mid and rearward areas, respectively, at the top side46of the housing24. The second attachment flange36and the third attachment flange38each include one or more fastener openings for fixing the headlamp structure12to the vehicle body structure14. With the headlamp structure12installed to the vehicle body structure14, and with fenders, front grill and trim elements fully installed to the vehicle10, the first, second, third and fourth attachment flanges34,36,38and40are all concealed, as shown inFIG. 1.

As shown inFIG. 3, the housing24(also referred to as a headlamp housing24) includes a main body50that defines a lamp cavity52. The top side46of the housing24includes the second and third attachment flanges36and38, as described above. The lamp cavity52is dimensioned to receive the aiming bracket26, the circuit board28and the reflector30in a manner described further below. The housing24further includes aiming structures that are also described in greater detail below.

A description of the aiming bracket26is now provided with specific reference toFIGS. 3, 6, and 8-15. The aiming bracket26is a multi-surface formed element that includes a reflector receiving area54that is shaped and contoured to receive the reflector30. Specifically, the reflector receiving area54includes a plurality of attachment structures56that retain the reflector30and the circuit board28securely to the aiming bracket26.

The aiming bracket26also includes aiming structures that are connected to corresponding aiming structures of the housing24. A description of aiming structures that adjustably secure the aiming bracket26to the housing24is now provided with specific reference toFIG. 3,

As shown inFIGS. 8, 10 and 11, a rear wall24aof the housing24has a rearward facing surface24b. The rear wall24aof the housing24includes a first aiming portion60. The aiming bracket26includes a second aiming portion62that aligns with the first aiming portion60with the aiming bracket26installed within the lamp cavity52of the housing24. As shown inFIGS. 10 and 11, the first aiming portion60includes a spherical shaped end that is retained by resilient members of the second aiming portion62. The spherical shaped end allows the aiming bracket26to pivot about the spherical shaped end. In other words, the first and second aiming portions60and62connect the housing24and the aiming bracket26to one another, but, allow the aiming bracket26to pivot during aiming adjustment relative to the housing24. Put another way, the first aiming portion60and the second aiming portion62, are engaged with one another such that aiming adjustment of the aiming bracket26causes movement of the contoured reflector panel30.

As shown inFIGS. 8, 12 and 13, the rear wall24aof the housing24includes a third aiming portion64. The aiming bracket26includes a fourth aiming portion66that aligns with the third aiming portion64with the aiming bracket26installed within the lamp cavity52of the housing24. As shown inFIGS. 12 and 13, the third aiming portion64includes threaded adjuster64athat threads into a threaded receiving structure66aof the fourth aiming portion66. Rotation of the threaded adjuster64acauses adjustment of the position of the reflector30and the aiming bracket26about a vertical axis that extends through the first and second aiming portions60and62. Consequently, the threaded adjuster64aaims a beam of light from the reflector30in either left or right directions relative to a forward direction of the vehicle10.

As shown inFIGS. 8, 14 and 15, the rear wall24aof the housing24includes a fifth aiming portion68. The aiming bracket26includes a sixth aiming portion70that aligns with the fifth aiming portion68with the aiming bracket26installed within the lamp cavity52of the housing24. As shown inFIGS. 14 and 15, the fifth aiming portion68includes threaded adjuster68athat threads into a threaded receiving structure70aof the sixth aiming portion70. Rotation of the threaded adjuster68acauses adjustment of the position of the reflector30and the aiming bracket26about a horizontal axis that extends through the first and second aiming portions60and62. Consequently, the threaded adjuster68aaims a beam of light from the reflector30in either up or down directions relative to a forward direction of the vehicle10.

The circuit board28includes electric circuits designed to operate headlamp components. The circuit board28includes a plurality of low beam light emitters80(for example, LEDs—light emitting diodes), a plurality of high beam light emitters82(for example, LEDs) shown inFIG. 7, heat sinks84and86(FIG. 8), and, heat dissipating fins88.

The circuit board28is attached to an upper end of the reflector30, as shown inFIGS. 7, 8 and 9via fasteners (not shown). The plurality of low beam light emitters80and the plurality of high beam light emitters82are aligned with predetermined reflector surface portions of the reflector30, as indicated inFIG. 7. The heat sinks84and86(shown in phantom inFIG. 8), are fixed via fasteners Fi to the aiming bracket26.

A description of the contoured reflector panel30(also referred to as the reflector30) is now provided with specific reference toFIGS. 3, 6 and 7. The reflector30has a forward-facing surface90, a rearward facing surface (not shown), an outboard end92(also referred to as an outboard side), an inboard end94(also referred to as an inboard side), and a reflex supporting portion96. The forward-facing surface90includes reflector surface portions100,102,104,106and108that are arranged vertically, side by side and extending along the forward-facing surface90between the inboard end92and the outboard end94. The reflex supporting portion96extends in the vehicle forward direction from the inboard end94of the reflector30.

The reflector surface portions100,102and104are for producing low beam illumination from the headlamp structure12, and the reflector surface portions106and108are for producing high beam illumination from the headlamp structure12, and usually operates in combination with the low beam illumination.

Each of the reflector surface portions100,102,104,106and108has a similar shape. Specifically, upper ends of each of the reflector surface portions100,102,104,106and108are rearward of the lower ends of corresponding ones of the reflector surface portions100,102,104,106and108. Further, each reflector surface portions100,102,104,106and108has a curved contour throughout their length and a semi-circular cross-section throughout their length, as shown inFIG. 7. In other words, each of the reflector surface portions100,102,104,106and108has a general shape that resembles a chute.

The plurality of low beam light emitters80(herein after referred to as the low beam LED80) and the plurality of high beam light emitters82(herein after referred to as the high beam LED82) are installed at corresponding upper ends of each of the reflector surface portions100,102,104,106and108, as shown in phantom inFIG. 7. More specifically, one low beam LED80is positioned at or near the top end of the reflector surface portions100, another low beam LED80is positioned at or near the top end of the reflector surface portions102, and still another low beam LED80is positioned at or near the top end of the reflector surface portions104.

Similarly, one high beam LED82is positioned at or near the top end of the reflector surface portions106, another high beam LED82is positioned at or near the top end of the reflector surface portions108. It should be understood from the drawings and the description herein that the LEDs80and82can be fixed to the reflector30, or, alternatively, can be fixed to the circuit board28.

Each of the reflector surface portions100,102,104,106and108is specifically shaped to reflect light from a corresponding one of the LEDs80and LEDs82. More specifically, each of the reflector surface portions100,102,104,106and108reflects and aims light from the corresponding one of the LEDs80and82and such that the reflected light shines in forward directions, as represented inFIG. 7by arrows L80and L82.

In the depicted embodiment, the reflector surface portions100,102,104,106and108, the reflex supporting portion96of the contoured reflector panel30are formed as a single, uniform, monolithic element.

During assembly of the headlamp structure12, the circuit board28is attached to an upper portion of the contoured reflector panel30, and, the reflex reflector32is snap-fitted and/or held by adhesive to the reflex supporting portion96. Thereafter, the assembled contoured reflector panel30, the reflex reflector32and the circuit board28are attached to the aiming bracket26. Thereafter, the contoured reflector panel30and the aiming bracket26are installed to the housing24and secured to the housing by the aiming portions60,62,64,66,68, and70. Consequently, operation of the aiming portions60,62,64,66,68, and70aim the aiming bracket and the contoured reflector panel30such that the reflected light from the contoured reflector panel30, as represented inFIG. 7by arrows L80and L82, can be aimed in accordance with predetermined parameters.

A description of the reflex reflector32is now provided with specific reference toFIGS. 3 and 7. As mentioned above, the reflex reflector32is snap-fitted and/or held by adhesive to the reflex supporting portion96of the reflector30. The reflex reflector32has an exposed surface that meets the SAE requirements of a reflex reflector. Specifically, the reflex reflector32is provided with either a textured surface, or internal texturing that affects the optical reflective properties of the material that defines the reflex reflector32, which is typically includes polymer(s) or plastic material(s). Hence, the reflex reflector32is not a mirror per se, but does reflect some of the light that shines directly on the exposed surface of the reflex reflector32. Specifically, incoming light represented inFIG. 7by the arrow LVcomes from a location outboard of the headlamp structure24(and outboard of the vehicle10). The light LVis partially diffused and partially reflected, but not in a direct reflection angle. Rather light reflected from the reflex reflector32, represented by the arrows LR, reflects back within a conical path that has boundaries angularly offset from the path of the light LV. Further, due to the optical characteristics of the reflex reflector32, the intensity of the light LRis greatly reduced, as compared to the intensity of the light LV.

Hence, the reflex reflector32is referred to herein as a passive reflector because it does not reflect all light it receives. Further, due to the geometry of the headlamp structure24, its location on the vehicle10, and the optical properties of the reflex reflector32, the only light that reaches the reflex reflector32for reflection, is light coming from a lateral side of the vehicle10. For example, when the vehicle10is at a stop light or a stop sign, or passing through an intersection, an “other” vehicle traveling along a path perpendicular to the vehicle10can shine its headlights on the reflex reflector32. The operator of the other vehicle will become aware of the vehicle10due to the light reflected by the reflex reflector32, where the light reflected from the reflex reflector32comes from the other vehicle.

As shown inFIG. 7, the reflector30of the headlamp structure24of the vehicle10, aims light in the vehicle forward direction, as indicated by the arrows L80and L82. The light LVreceived by the reflex reflector32comes from a lateral outboard side thereof with the light LVprojecting in a direction that is perpendicular or approximately perpendicular to the direction of the projection of the light indicated by the arrows L80and L82. The light reflected by the reflex reflector32projects from the reflex reflector generally within the cone defined by the arrows LR(reflected light). The arrows LRare approximately perpendicular to the path of the light from the headlamp structure24, as represented by the arrows L80and L82.

Hence, light from the low beam light emitters80(LEDs80) and the high beam light emitters82(LEDs82) located at the top side proximate respective upper ends of corresponding ones of the plurality of reflector surface portions100,102,104,106and108is directed in a vehicle forward direction perpendicular to the inboard direction DIand the outboard direction Do of the vehicle10. For purposes of clarity, the LEDs80and82, and the reflector surface portions100,102,104,106and108are active lighting structures. Whereas the reflector surface of the passive reflector32(the reflex reflector32) is configured and oriented such that at least a portion of light approaching the reflex reflector32from outboard of the outboard side of the contoured reflector panel is reflected back in the outboard direction.

The various vehicle elements and components of the vehicle10, other than the headlamp structure12, are conventional elements and components that are well known in the art. Since such elements and components are well known in the art, these structures will not be discussed or illustrated in detail herein. Rather, it will be apparent to those skilled in the art from this disclosure that the components can be any type of structure and/or programming that can be used to carry out the present invention.

General Interpretation of Terms

The term “configured” as used herein to describe a component, section or part of a device includes structures are that is constructed to carry out the desired function.