Patent ID: 12194911

DETAILED DESCRIPTION

Advantages and features of the present disclosure and methods of accomplishing the same may be understood more readily by reference to the following detailed description of exemplary embodiments and the accompanying drawings. The present disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the concept of the disclosure to those skilled in the art, and the present disclosure will only be defined by the appended claims. Throughout the specification, like reference numerals in the drawings denote like elements.

In some embodiments, well-known steps, structures and techniques will not be described in detail to avoid obscuring the invention.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Embodiments of the disclosure are described herein with reference to plan and cross-sectional illustrations that are schematic illustrations of exemplary embodiments of the disclosure. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments of the disclosure should not be construed as limited to the particular shapes of regions illustrated herein but should be construed to include deviations in shapes that result, for example, from manufacturing. In the drawings, respective components may be enlarged or reduced in size for convenience of explanation.

Hereinafter, the present disclosure will be described with reference to the accompanying drawings for describing a vehicle lamp according to embodiments of the present disclosure.

FIGS.1and2are perspective views of a vehicle lamp according to an embodiment of the present disclosure,FIG.3is a side view of the vehicle lamp according to an embodiment of the present disclosure,FIG.4is a plan view of the vehicle lamp according to an embodiment of the present disclosure, andFIG.5is a cross-sectional view taken along line A-A′ ofFIG.1.

Referring toFIGS.1through5, a vehicle lamp1may include a plurality of lamp modules1000, and the beam patterns formed by the lamp modules1000may collectively generate a suitable beam pattern for the intended purpose of the vehicle lamp1.

For convenience, the vehicle lamp1will hereinafter be described as being for use as, for example, a headlamp to ensure forward visibility during low-light conditions (e.g., nighttime driving), but the present disclosure is not limited thereto. The vehicle lamp1may also serve various other lamp functions of vehicles, including, but not limited to, tail lamps, brake lamps, turn signal lamps, fog lamps, backup lamps, and position lamps.

When used as a headlamp, the vehicle lamp1may produce a low beam pattern that ensures a wide field of vision for nearby areas in front of the vehicle by directing light downward below a cutoff line to prevent glare for the drivers of front vehicles such as preceding vehicles or oncoming vehicles. Additionally, the vehicle lamp1may generate a high beam pattern that extends the field of view to distant areas in front of the vehicle. Hereinbelow, the vehicle lamp1that generates a low beam pattern will be described by way of example.

The plurality of lamp modules1000may be arranged in at least one direction depending on the layout or design of the vehicle lamp1. Hereinbelow, the plurality of lamp modules1000will be described as being arranged in a vertical direction by way of example, which allows for the realization of a slimmer exterior form factor.

The beam pattern produced by the vehicle lamp1may result from the overlap of identical sub-beam patterns generated by the plurality of lamp modules1000, or from the combination of different sub-beam patterns generated by different lamp modules among the plurality of lamp modules1000.

For example, in a case where the vehicle lamp1generates a low beam pattern, identical low beam patterns formed by the lamp modules1000, each including a high-intensity region and a spread region, may be configured to overlap with one another. Alternatively, a high-intensity region formed by one of the lamp modules1000and a spread region formed by another one of the lamp modules1000may be synthesized together.

FIG.6is a longitudinal cross-sectional view of a lamp module according to an embodiment of the present invention.FIG.6illustrates one of the plurality of lamp modules1000, and the forthcoming description can readily apply to the remaining lamp modules1000.

Referring toFIG.6, a lamp module1000may include a light source1100, an optical guide unit1200, and an optical lens1300.

The light source1100may emit light with an appropriate color and/or luminous flux suitable for the intended purpose of the vehicle lamp1. For example, a semiconductor light-emitting device such as a light-emitting diode (LED) may be used as the light source1100, but the present disclosure is not limited thereto. Various other light sources such as laser diodes (LDs) or bulbs may also be used. Depending on the type of the light source1100, optical elements such as mirrors, prisms, reflectors, or phosphors may be additionally used.

An optical guide unit1200may be disposed in front of the light source1100to guide incident light from the light source1100toward the optical lens1300, which is disposed in front of the optical guide unit1200. The light source1100may be disposed with its emission surface facing forward, allowing the light to be incident upon the optical guide unit1200.

The configuration that the optical guide unit1200is disposed in front of the light source1100, and the optical lens1300is disposed in front of the optical guide unit1200is based an example that the vehicle lamp1emits light forward, but the notion of forward may vary depending on the installation position and direction of the vehicle lamp1.

The optical guide unit1200may include an entrance section1210, an exit section1220, and a transmission section1230. In some embodiments, the optical guide unit120may further include a shield section1240.

The entrance section1210may allow incident light from the light source1100to be condensed.

The entrance section1210may have a central surface1211, which is centered around an optical axis Ax of the light source1100, a protruding surface1212that protrudes toward the light source1100from the edges of the central surface1211, and a reflective surface1213that reflects the light incident on the protruding surface1212forward. The reflective surface1213may be formed such that its distance from the optical axis Ax of the light source1100gradually increases in a direction from its rear end connected to the protruding edge of the protruding surface1212to its front end, thereby allowing the light incident upon the protruding surface1212to be reflected substantially forward.

The exit section1220may allow at least some of the incident light from the entrance section1210to exit and enter the optical lens1300. The exit section1220may be formed with a convex shape toward the front to concentrate the exiting light, thereby enabling it to enter the optical lens1300with minimal loss.

Since the entrance section1210and the exit section1220are connected by the transmission section1230to form an integral unit, the configuration of the lamp module1000can be simplified compared to a case where the entrance section1210and the exit section1220are separate and installed individually. The light incident upon the entrance section1210may be transmitted to the exit section1220through the transmission section1230.

The shield section1240may be formed with a concave shape on one side of the transmission section1230to obstruct some of the light proceeding to the exit section1220. In an example where the vehicle lamp1generates a low beam pattern, the shield section1240may be formed with a concave shape upward on a lower side of the transmission section1230. In this case, the height of the cutoff line of the low beam pattern generated by the vehicle lamp1may be varied depending on the height of an upper part of the shield section1240.

The shield section1240, which is disposed with its upper part at or near a rear focus F of the exit section1220, may obstruct some of the light proceeding from the entrance section1210to the exit section1220, thereby allowing the cutoff line of the low beam pattern to be formed.

However, the surface of the transmission section1230where the shield section1240is formed is not particularly limited to the above-described configuration and may be varied depending on the beam pattern to be generated by the vehicle lamp1.

FIG.7is a lateral cross-sectional view illustrating an upper part of a shield section according to an embodiment of the present disclosure, andFIG.8is an enlarged view of the upper part of the shield section illustrating a protruding portion according to an embodiment of the present disclosure.

Referring toFIGS.7and8, the upper part of the shield section1240may include a first edge portion1241and a second edge portion1242, which are disposed on both lateral sides of the optical axis Ax of the light source1100and have different heights, and a connecting portion1243, which is between the first edge portion1241and the second edge portion1242. By way of example, the second edge portion1242may be disposed higher than the first edge portion1241.

Referring toFIG.9, when the first edge portion1241, the second edge portion1242, and the connecting portion1243are formed at the top of the shield section1240, as described above, a cutoff line CL of a low beam pattern generated by the vehicle lamp1may include an upper line CL1formed by the first edge portion1241, a lower line CL2formed by the second edge portion1242, and a connecting line CL3formed by the connecting portion1243that connects the upper and lower lines CL1and CL2.

In this case, the upper line CL1may correspond to the lane that the vehicle is currently driving in, and the lower line CL2may correspond to an opposing lane. The first and second edge portions1241and1242may be formed with different heights such that the upper and lower lines CL1and CL2may have different heights, but the present disclosure is not limited thereto. In other words, any one of the first and second edge portions1241and1242may be formed to be higher than the other, or the first and second edge portions1241and1242may both have the same height, depending on the shape of the cutoff line CL to be formed. No connecting portion may be provided where the first and second edge portions1241and1242have the same height.

The first and second edge portions1241and1242may be formed to be substantially parallel to ensure that the upper and lower lines CL1and CL2are formed horizontally since a protrusion or recess in either the upper or lower line CL1or CL2may result in reduced visibility or occurrence of glare for the driver of an oncoming vehicle.

Further, the shield section1240may include a protruding portion1244, which is formed to protrude upward from the second edge portion1242. Consequently, referring toFIG.10, a section S of the lower line CL2, where an oncoming vehicle is disposed, may be depressed, thereby preventing glare for the driver of the oncoming vehicle.

In other words, the lower line CL2, which is formed by the second edge portion1242, may preferably be formed to be as horizontal as possible, but due to the potential for glare based on the position of the oncoming vehicle, the section S of the lower line CL2may be recessed, thereby more effectively preventing glare for the driver of the oncoming vehicle.

The protruding portion1244may include a third edge portion1244aand a fourth edge portion1244b, which are formed along a left-right direction. The third and fourth edge portions1244aand1244bmay be sloped in opposite directions, i.e., from left to right and from right to left, such that abutting ends thereof are positioned higher than the second edge portion1242, and the other ends are connected to the second edge portion1242.

The third edge portion1244amay form a first inclined line CL4, which slopes downward from its end connected to the lower line CL2, moving away from the connecting line CL3along the left-right direction, and the fourth edge portion1244bmay form a second inclined line CL5, which slopes upward from its end connected to the first inclined line CL4, moving away from the connecting line CL3along the left-right direction to be connected to the lower line CL2.

In this case, the third edge portion1244amay be disposed closer to the connecting portion1243compared to the fourth edge portion1244b. A width d1, in the left-right direction, of the third edge portion1244amay be narrower than a width d2, in the left-right direction, of the fourth edge portion1244b. As a result, an inclination angle θ1of the third edge portion1244amay be greater than an inclination angle θ2of the fourth edge portion1244bwith respect to the second edge portion1242.

If the third and fourth edge portions1244aand1244bhave the same inclination angle and widths in the left-to-right direction, abrupt shifts may emerge in the section S of the lower line CL2, instigating a sense of incongruity. To alleviate this, the third edge portion1244amay be formed to have a smaller inclination angle yet a greater length compared to the fourth edge portion1244b. As a result, the section S of the lower line CL2can transition more gently and naturally, and the sense of incongruity can be reduced.

The optical lens1300may be configured such that the incident light that is guided by the optical guide unit1200enters through an entrance surface1310and exit through an exit surface1320, thereby forming a beam pattern suited to the intended purpose of the vehicle lamp1.

The exit surface1320of the optical lens1300may be divided into a plurality of facets1321, and the shape, size, inclination angle, and curvature of each of the facets1321may be determined based on the distribution characteristics of the beam pattern to be formed by the lamp module1000, i.e., the location, size, shape, and brightness of the area where light is projected by the lamp module1000.

Meanwhile, the relative positions of the optical guide unit1200and the optical lens1300in each of the lamp modules1000may be variously arranged depending on the body lines of the vehicle.

Specifically, the vehicle lamp1may reside within the internal space formed by a lamp housing and an outer lens that is coupled to the lamp housing. The outer surface shape of the outer lens, which shapes parts of the body contour of the vehicle, may not adopt a flat shape facing the front of the vehicle. Instead, the outer lens may be inclined or curved in at least one direction from one side to the other side of the vehicle. In this case, the vehicle lamp1may be arranged along the shape of the outer lens.

For example, if the outer lens is configured to be disposed more forward as it descends from the top to the bottom of the vehicle lamp1, as illustrated inFIG.3, the optical guide unit1200in each of the lamp modules1000may also be formed with a greater length in a front-rear direction, descending from the top to the bottom of the vehicle lamp1. Similarly, the optical lens1300in each of the lamp modules1000may be tilted such that the bottom thereof is disposed more forward than the top thereof.

Assuming that the positions of the entrance portions1210of the lamp modules1000are identical (i.e., aligned flush vertically), the exit portions1220of the lamp modules1000may be disposed more forward, descending from the top to the bottom of the vehicle lamp1. Consequently, the optical guide units120of the lamp modules1000may also become longer in the front-rear direction, descending from the top to the bottom of the vehicle lamp1.

Furthermore, as illustrated inFIG.4, in a case where the outer lens is formed to be positioned clear to the rear in a direction from the inner side to the outer side of the vehicle as well as in a direction from the bottom to the top, the optical guide units1200of the lamp modules1000may also be disposed closer to the inner side of the vehicle along the left-right direction, descending from the top to the bottom of the vehicle lamp1. Similarly, the optical lenses1300of the lamp modules1000may also be tilted such that the inner side of optical lenses1300is disposed more forward than the outer side thereof.

To simplify the configuration of the lamp modules1000, the plurality of lamp modules1000may be integrally formed. In this case, the light sources1100of the lamp modules1000may be installed on a common substrate, and the optical guide units1200and the optical lenses1300of the lamp modules1000may be integrally formed with each other.

When the optical lenses1300of the lamp modules1000are integrally formed, the entrance surfaces1310of the optical lenses1300of the lamp modules1000may form a continuous and smooth surface without steps (e.g., ridges, articulations, or lines) formed therebetween. In this case, control of optical paths can be facilitated more easily.

A case where the lamp modules1000are integrally formed in a vertical direction based on the arrangement direction of the lamp modules1000will hereinafter be described. In this case, the lamp modules1000may be collectively assembled together, thereby simplifying the entire assembly process.

FIG.11is a cross-sectional view illustrating an aperture according to an embodiment of the present disclosure.

Referring toFIG.11, in a case where the optical guide units1200of the lamp modules1000are integrally formed, an aperture1250may be formed between adjacent optical guide units1200to form the shield sections1240. The width of the aperture1250may gradually increase along the left-right direction in consideration of the direction where a mold for forming the aperture1250is separated.

In other words, if the width of the aperture1250increases in the opposite direction to the direction where the mold is separated, the mold may not be able to be easily separated. Thus, by increasing the width of the aperture1250in the direction where the mold is separated, any undercuts can be prevented during the separation of the mold.

As mentioned earlier, as the light sources1100, the optical guide units1200, and the optical lenses1300of the lamp modules1000may be integrally formed, the number of components of the vehicle lamp1may be reduced, and the assembly of the vehicle lamp1may be simplified.

Furthermore, as the shield section1240of each of the lamp modules1000includes the first edge portion1241, the second edge portion1242, the connecting portion1243, and the protruding portion1244, the section S of the lower line CL2formed by the second edge portion1242where an oncoming vehicle is disposed can be depressed, thereby preventing glare for the driver of the oncoming vehicle.

In concluding the detailed description, those skilled in the art will appreciate that many variations and modifications can be made to the exemplary embodiments without substantially departing from the principles of the present disclosure. Therefore, the disclosed exemplary embodiments are used in a generic and descriptive sense only and not for purposes of limitation.