The present application claims priority to Korean Patent Application No. 10-2015-0121779, fried Aug. 28, 2015, the entire contents of which is incorporated herein for all purposes by this reference.
Field of the Invention
The present invention relates to an automotive headlamp module and, more particularly, to a module used at a low cost by simplifying components thereof and that implements a beam pattern in a low-beam mode when a fail-safe function is performed due to breakdown in a high-beam mode or an adaptive driving-beam mode.
Description of the Related Art
Generally, beam patterns formed by automotive headlamp modules are classified into a low-beam mode, a high-beam mode, and an adaptive driving-beam (e.g., ADB) mode. For example, the ADB mode, automatically adjusts the direction and angle of light based on the driving conditions, and is a technology that automatically adjusts into a high-beam mode and a low-beam mode by sensing a vehicle ahead using a an imaging device. Further, when another vehicle is disposed ahead of the vehicle, the ADB mode enables a driver to comfortably drive without blinding the driver by the light of an approaching vehicle.
A headlamp module of the related art, as show in
The shield 2 includes a high-beam protrusion 2a, a low-beam protrusion 2b, and an ADB protrusion 2c that protrudes radially. For example, when the shield 2 is rotated and the high-beam protrusion 2a is disposed ahead of the light source 7, a beam pattern of the high-beam mode is implemented. When the low-beam protrusion 2b is disposed ahead of the light source 7, a beam pattern of the low-beam mode is implemented. Further when the ADB protrusion 2c is disposed ahead of the light source 7, a beam pattern of the ADB mode is implemented.
The shield motor 3, is not a common direct current (e.g., DC) motor, but a stepping motor, that accurately adjusts a rotational angle of the shield 2, but has a disadvantage of high price. Moreover, a specific sensor 10 to detect a rotational position and a complex control logic is required, thereby making implementation difficult in common low-cost vehicles.
The case motor 9 is an Intelligent Smart Motor (ISM) that preforms a fail-safe function and the beam pattern in the high-beam mode or the ADB mode is higher than the beam pattern in the low-beam mode. For example, when a problem occurs with the shield motor 3 or the headlamp, the driver of an approaching vehicle may have their field of vision impacted thus potentially contributing to an accident. In other words, the case motor 9 is an ISM motor that communicates to recognize a breakdown mode. Upon recognition of a breakdown mode, the motor rotates the exterior case 8 to rotate the shield housing 1 and the reflector 6 coupled to the exterior case 8 downward, thereby adjusting the beam pattern from the headlamp to be lowered to the ground. However, when the headlamp module of the related art performs a fail-safe function in the high-beam mode or the ADB mode, the beam pattern in the high-beam mode or the beam pattern of the ADB mode is the beam pattern in the fail-safe mode.
Further, the beam pattern in the fail-safe mode does not cross over a cutoff line of a low beam, therefore the beam pattern in a fail-safe mode in the related art is formed in a downward direction substantially proximate to the ground. Additionally, performance deteriorates compared to a low beam state, thereby reducing safety during operation of the vehicle. When the beam pattern in the fail-safe mode crosses over the cutoff line of a low beam, the beam pattern becomes the same as the high-beam mode state, in which the driver's field of vision in an approaching vehicle is impacted. For example,
The foregoing is intended merely to aid in the understanding of the background of the present invention, and is not intended to mean that the present invention falls within the purview of the related art that is already known to those skilled in the art.
The present invention provides an automotive headlamp module that reduces manufacturing cost and that maybe used for common low-cost vehicles by implementing beam patterns in a high-beam mode, a low-beam mode, and an ADB mode, by simplifying components thereof and using low-cost components. Further, the present invention provides an automotive headlamp module that ensures a sufficient visual range for a driver and provides safety during operation of the vehicle by implementing a beam pattern in a low-beam mode upon engagement of a fail-safe function due to breakdown in a high-beam mode or an ADB mode.
In one aspect, according to an exemplary embodiment of the present invention, an automotive headlamp module may include a drum type shield rotatably disposed with respect to a shield housing and having a high-beam protrusion, a low-beam protrusion, and an ADB protrusion disposed on an exterior side. Further, a shield disc may be coupled to the shield to rotate with the shield and may have a rotational angle adjusted by the shield housing. A housing disc guided movable in a longitudinal direction of the shield by the shield housing and having an end in contact with the shield disc. Additionally, a return spring having both ends supported by the shield housing and the housing disc may press the housing disc to the shield disc utilizing the accumulated elastic force.
The automotive headlamp module may further include a direct current (DC) motor coupled to the shield housing that produces power to adjust the shield a PCB that may be coupled to the shield housing and may be configured to operate the DC motor and a power transmission gear that connects ends of the DC motor and the shield to each other and transmits power. The automotive headlamp module may further include a reflector coupled with the shield housing, a light source disposed on the reflector, an exterior case that couples the shield housing and the reflector and a case motor that couples the exterior case and provides power for rotating the exterior case to perform a fail-safe function.
An upper stopper and a lower stopper may be configured to adjust the rotational angle of the shield disc by coming in contact with the shield disc when the shield disc is rotated to be vertically arranged at a predetermined distance within the shield housing. The shield disc may include a shank coupled to the shield, that extends in a longitudinal direction of the shield, and inserted rotatably within the a shaft guide formed within the shield housing, and a male connector that extends in a longitudinal direction of the shank, disposed between the upper stopper and the lower stopper, and having a front side divided into a plurality (e.g., two) components by inclined surfaces that have about the same inclination. Further, a disc protrusion formed on the exterior side of the male connector and configured to adjust the rotational angle of the shield disc by coming in contact with the upper stopper and the lower stopper when the shield disc is rotated may be included.
In some exemplary embodiments, a disc guide into which the housing disc is inserted may be formed at a side (e.g., proximate to) the upper and lower stoppers within the shield housing. The housing disc may be restricted in rotation and translates in the longitudinal direction of the shield by the disc guide. The housing disc may include a rectangular parallel piped body that may be inserted in the disc guide, a male connector that protrudes toward the shield on a first side of the body and has a connector groove at a front side that fitted on the inclined surfaces of the male connector to contact the shield disc and a shank that extends in the longitudinal direction of the shield on a second side of the body and translates in the longitudinal direction of the shield through an exterior flange of the shield housing.
The return spring may be fitted on the shank of the housing disc, having a first end supported on the body of the housing disc and a second end supported on an interior side of the exterior flange of the shield housing.
In other exemplary embodiments, shapes of the inclined surfaces of the male connector and a shape of the connector groove of the female connector may coupled to each other, when the shield disc is rotated with the shield and the inclined surfaces of the male connector extends from the connector groove of the female connector. Further, the housing disc may translate in a linear trajectory from the shield disc against a force exerted by the return spring and with the housing disc translates away from the shield disc. Additionally, when the shapes of the inclined surfaces correspond to the shape of the connector groove or power supplied to the DC motor is disengaged, the housing disc may translate in a linear trajectory toward the shield disc by return force of the return spring and the shapes of the inclined surfaces and the shape of the connector groove may correspond to each other.
According to the vehicle headlamp module, rotational force may be applied to the shield by a common DC motor, compared to using a stepping motor, thereby providing a cost and component reduction. Accordingly, application of the headlamp module may be feasible for use in common low-cost vehicles. Further, according to an exemplary embodiment, a sufficient visual range for a driver even in an emergency may be provided and may provide enhanced safety during operation of the vehicle by implementing a beam pattern in a low-beam mode when a fail-safe function is performed due to breakdown in a high-beam mode or an ADB mode.
The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description when taken in conjunction with the accompanying drawings:
An automotive headlamp module according to exemplary embodiments of the present invention is described hereafter in detail with reference to the accompanying drawings. In the following detailed description, only certain exemplary embodiments of the present invention have been shown and described, simply by way of illustration. As those skilled in the art would realize, the described exemplary embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention. Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive. Like reference numerals designate like elements throughout the specification.
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. For example, in order to make the description of the present invention clear, unrelated parts are not shown and, the thicknesses of layers and regions are exaggerated for clarity. Further, when it is stated that a layer is “on” another layer or substrate, the layer may be directly on another layer or substrate or a third layer may be disposed therebetween.
Unless specifically stated or obvious from context, as used herein, the term “about” is understood as within a range of normal tolerance in the art, for example within 2 standard deviations of the mean. “About” can be understood as within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the stated value. Unless otherwise clear from the context, all numerical values provided herein are modified by the term “about.”
It is understood that the term “vehicle” or “vehicular” or other similar term as used herein is inclusive of motor vehicles in general such as passenger automobiles including sports utility vehicles (SUV), buses, trucks, various commercial vehicles, watercraft including a variety of boats and ships, aircraft, and the like, and includes hybrid vehicles, electric vehicles, combustion, plug-in hybrid electric vehicles, hydrogen-powered vehicles and other alternative fuel vehicles (e.g. fuels derived from resources other than petroleum). An automotive headlamp module according to an exemplary embodiment of the present invention, as shown in
The present invention may further include a DC motor 70 fixed to the shield housing 20 configured to produce power to translate the shield 30, a PCB 80 coupled to the shield housing 20 and configured to operate the DC motor 70, and a power transmission gear 90 connecting ends of the DC motor 70 and the shield 30 that transmit power. Further, included may be a reflector 100 coupled to the shield housing 20; a light source 110 disposed on the reflector 100, an exterior case 120 that couples the shield housing 20 and the reflector 100 and a case motor 130 coupled to the exterior case 120 and provides power for rotating the exterior case 120 to perform a fail-safe function.
In particular, when the shield 30 is rotated and the high-beam protrusion 31 is disposed ahead of the light source 110, a beam pattern in a high-beam mode may be implemented, when the low-beam protrusion 32 is disposed ahead of the light source 110, a beam pattern in the low-beam mode may be implemented, and when the ADB protrusion 33 is disposed ahead of the light source 110, a beam pattern in an ADB mode may be implemented. The present invention may provide a rotational force to the shield 30 from the common DC motor 70, and advantageously reduces the manufacturing cost in comparison to using a stepping motor for a shield motor in the related art. Further, the present invention does not require a specific sensor or a complex control logic, as required by the related art, to detect the rotational position of the shield 30, since it uses the DC motor 70. Accordingly the cost may be reduced thereby making the technology feasible for use in common low-cost vehicles.
The case motor 130 may be an Intelligent Smart Motor (ISM) configured to preform a fail-safe function and the beam pattern in the high-beam mode or the ADB mode may be higher than the beam pattern in the low-beam mode. For example, when a problem occurs (e.g., an error or a failure) with the DC motor 70 or the headlamp, the driver of an approaching vehicle may have a field of vision obstructed (e.g., blinded) thus possibly contributing to an accident In other words, the case motor 130 may be an ISM motor that may communicate to recognize a breakdown mode. Upon recognition of a breakdown mode, the exterior case 120 may be rotated and the shield housing 20 and the reflector 110 equipped with the light source 110, coupled to the exterior case 120, may be rotated downward. Thus the beam pattern from the headlamp may be lowered to the ground.
According to headlamp modules of the related art, when a fail-safe function is performed in a high-beam mode or an ADB mode, the beam pattern in the high-beam mode or the beam pattern in the ADB mode is the beam pattern in a fail-safe mode and the beam pattern in the fail-safe mode is not supposed cross over a cutoff of a low beam, is the beam pattern is formed proximate to the ground. Accordingly, in the headlamp modules of the related art, performance is reduced in the beam pattern in the fail-safe mode in comparison to the beam pattern in the low-beam mode.
However, according to an exemplary embodiment of the present invention, since the beam pattern in the low-beam mode may be implemented upon performance of the fail-safe function due to breakdown in the high-beam mode or the ADB mode by the shield disc 40, housing disc 50, and return spring 60, and the shield housing 20 receiving them, a sufficient visual range for a driver and safety during operation of the vehicle may be ensured. In other words, an upper stopper 21 and a lower stopper 22 configured to adjust the rotational angle of the shield disc 40 by coming in contact with the shield disc 40 when the shield disc 40 is rotated are vertically arranged at a predetermined distance within the shield housing 20 and a disc guide 23 into which the housing disc 50 may be formed at a side from the upper and lower stoppers 21 and 22. Accordingly, the disc guide 23 may prevent rotation of the housing disc 50, and the housing disc 50 may translate in the longitudinal direction of the shield 30. Namely, the disc guide 23 may be formed in a U-shape with a side open, but is not limited thereto.
The shield disc 40 may include a shank 41 coupled to the shield 30, that extends in the longitudinal direction of the shield 30, and may be inserted rotatably in the shaft guide 24 formed in the interior of the shield housing 20. A male connector 42 may extend in the longitudinal direction of the shank 41, may be disposed between the upper stopper 21 and the lower stopper 22, and may have a runt side divided into a plurality (e.g., two) components by inclined surfaces 42a having about the same inclination; and a disc protrusion 43 may be formed on the exterior side of the male connector 42 and may be configured to adjust the rotational angle of the shield disc 40 by contact with the upper stopper 21 and the lower stopper 22 upon rotation of the shield disc 40.
The housing disc 50 may include a rectangular parallel piped body 51 inserted in the disc guide 23, a male connector 52 that protrudes toward the shield 30 on a first side of the body 51 and having a connector groove 52a at the front side fitted on the inclined surfaces 42a of the male connector 42 to contact with the shield disc 40 and a shank 53 that extends in the longitudinal direction of the shield 30 on a second side of the body 51 and translates in the longitudinal direction of the shield 30 through an exterior flange 25 of the shield housing 20. The return spring 60 may be coupled to the shank 53 of the housing disc 50, with a first end supported on the body 51 of the housing disc 50 and a second end supported on the interior side of the exterior flange 25 of the shield housing 20.
The operation of an exemplary embodiment of the present invention is described hereafter.
Furthermore, when the DC motor 70 or the driving system for the headlamp breaks in the high-beam mode or the ADB mode, as in
Moreover, when the power supplied to the DC motor 70 is disengaged with the fail-safe function, the housing disc 50 that has translated to the farthest position from the shied disc 40 may be translated in a linear trajectory toward the shield disc 40 by the return force of the return spring 60. Additionally the shield disc 40 and the housing disc 50 may be coupled to each other with the inclined surfaces 42a of the male connector 42 fully inserted within the connector groove 52a of the male connector 52. The shapes of the inclined surfaces 42a correspond to the shape of the connector groove 52a, and the disc protrusion 43 of the shield disc 40 may be disposed between the upper and lower stoppers 21 and 22. Accordingly, in the headlamp module of the present invention, the low-beam protrusion 32 on the shield 30 may be disposed ahead of the light source 110, the beam pattern B11 in the low-beam mode shown in
As described above, as the beam pattern B11 in the low-beam mode may be implemented when the fail-safe function is performed due to breakdown in the high-beam mode or the ADB mode. Additionally a sufficient visual range may be ensured for a driver even in an emergency, so safety the vehicle may be safely operated.
Although an exemplary embodiment of the present invention has been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
Number | Date | Country | Kind |
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10-2015-0121779 | Aug 2015 | KR | national |
Number | Name | Date | Kind |
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5707129 | Kobayashi | Jan 1998 | A |
Number | Date | Country |
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2010-015693 | Jan 2010 | JP |
2010-086863 | Apr 2010 | JP |
2012-164656 | Aug 2012 | JP |
10-2012-005027 | May 2012 | KR |
10-2012-0050271 | May 2012 | KR |
10-2012-007008 | Jun 2012 | KR |
10-2012-0070081 | Jun 2012 | KR |
10-2013-0082351 | Jul 2013 | KR |
Number | Date | Country | |
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20170059111 A1 | Mar 2017 | US |