Patent Application
20200132270
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.
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.
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.
Referring now to the attached drawings which form a part of this original disclosure:
Selected embodiments will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following descriptions of the embodiments are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
Referring initially to
The front end of the vehicle 10 is depicted in
The vehicle 10 has a vehicle body structure 14 with a driver's side 16 and a passenger's side 18. There are two headlamp structures 12, each basically being the same with identical features, except that the headlamp structures 12 are symmetrically arranged with respect to one another, being mirror images of one another. One of the headlamp structures 12 is installed to the front end of the vehicle 10 at the driver's side 16 thereof, with the other of the headlamp structures 12 being installed to the front end of the vehicle 10 at the passenger's side 18 thereof, as shown in
One of the headlamp structures 12 is depicted in
As shown in
As shown in
The headlamp structure 12 basically includes the housing 24, an aiming bracket 26, a circuit board 28, a contoured reflector panel 30 and a reflex reflector 32. The aiming bracket 26, the circuit board 28 and the contoured reflector panel 30 are all installed within the housing 24, and, are then covered and sealed within the housing 24 by the attachment of the lens 22 to the housing 24.
As show in
The second attachment flange 36 and the third attachment flange 38 are both part of the housing 24. More specifically, the second attachment flange 36 and the third attachment flange 38 are molded simultaneously with the housing 24 are 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 flange 36 and the third attachment flange 38 are formed along mid and rearward areas, respectively, at the top side 46 of the housing 24. The second attachment flange 36 and the third attachment flange 38 each include one or more fastener openings for fixing the headlamp structure 12 to the vehicle body structure 14. With the headlamp structure 12 installed to the vehicle body structure 14, and with fenders, front grill and trim elements fully installed to the vehicle 10, the first, second, third and fourth attachment flanges 34, 36, 38 and 40 are all concealed, as shown in
As shown in
A description of the aiming bracket 26 is now provided with specific reference to
The aiming bracket 26 also includes aiming structures that are connected to corresponding aiming structures of the housing 24. A description of aiming structures that adjustably secure the aiming bracket 26 to the housing 24 is now provided with specific reference to
As shown in
As shown in
As shown in
The circuit board 28 includes electric circuits designed to operate headlamp components. The circuit board 28 includes a plurality of low beam light emitters 80 (for example, LEDs—light emitting diodes), a plurality of high beam light emitters 82 (for example, LEDs) shown in
The circuit board 28 is attached to an upper end of the reflector 30, as shown in
A description of the contoured reflector panel 30 (also referred to as the reflector 30) is now provided with specific reference to
The reflector surface portions 100, 102 and 104 are for producing low beam illumination from the headlamp structure 12, and the reflector surface portions 106 and 108 are for producing high beam illumination from the headlamp structure 12, and usually operates in combination with the low beam illumination.
Each of the reflector surface portions 100, 102, 104, 106 and 108 has a similar shape. Specifically, upper ends of each of the reflector surface portions 100, 102, 104, 106 and 108 are rearward of the lower ends of corresponding ones of the reflector surface portions 100, 102, 104, 106 and 108. Further, each reflector surface portions 100, 102, 104, 106 and 108 has a curved contour throughout their length and a semi-circular cross-section throughout their length, as shown in
The plurality of low beam light emitters 80 (herein after referred to as the low beam LED 80) and the plurality of high beam light emitters 82 (herein after referred to as the high beam LED 82) are installed at corresponding upper ends of each of the reflector surface portions 100, 102, 104, 106 and 108, as shown in phantom in
Similarly, one high beam LED 82 is positioned at or near the top end of the reflector surface portions 106, another high beam LED 82 is positioned at or near the top end of the reflector surface portions 108. It should be understood from the drawings and the description herein that the LEDs 80 and 82 can be fixed to the reflector 30, or, alternatively, can be fixed to the circuit board 28.
Each of the reflector surface portions 100, 102, 104, 106 and 108 is specifically shaped to reflect light from a corresponding one of the LEDs 80 and LEDs 82. More specifically, each of the reflector surface portions 100, 102, 104, 106 and 108 reflects and aims light from the corresponding one of the LEDs 80 and 82 and such that the reflected light shines in forward directions, as represented in
In the depicted embodiment, the reflector surface portions 100, 102, 104, 106 and 108, the reflex supporting portion 96 of the contoured reflector panel 30 are formed as a single, uniform, monolithic element.
During assembly of the headlamp structure 12, the circuit board 28 is attached to an upper portion of the contoured reflector panel 30, and, the reflex reflector 32 is snap-fitted and/or held by adhesive to the reflex supporting portion 96. Thereafter, the assembled contoured reflector panel 30, the reflex reflector 32 and the circuit board 28 are attached to the aiming bracket 26. Thereafter, the contoured reflector panel 30 and the aiming bracket 26 are installed to the housing 24 and secured to the housing by the aiming portions 60, 62, 64, 66, 68, and 70. Consequently, operation of the aiming portions 60, 62, 64, 66, 68, and 70 aim the aiming bracket and the contoured reflector panel 30 such that the reflected light from the contoured reflector panel 30, as represented in
A description of the reflex reflector 32 is now provided with specific reference to
Hence, the reflex reflector 32 is referred to herein as a passive reflector because it does not reflect all light it receives. Further, due to the geometry of the headlamp structure 24, its location on the vehicle 10, and the optical properties of the reflex reflector 32, the only light that reaches the reflex reflector 32 for reflection, is light coming from a lateral side of the vehicle 10. For example, when the vehicle 10 is at a stop light or a stop sign, or passing through an intersection, an “other” vehicle traveling along a path perpendicular to the vehicle 10 can shine its headlights on the reflex reflector 32. The operator of the other vehicle will become aware of the vehicle 10 due to the light reflected by the reflex reflector 32, where the light reflected from the reflex reflector 32 comes from the other vehicle.
As shown in
Hence, light from the low beam light emitters 80 (LEDs 80) and the high beam light emitters 82 (LEDs 82) located at the top side proximate respective upper ends of corresponding ones of the plurality of reflector surface portions 100, 102, 104, 106 and 108 is directed in a vehicle forward direction perpendicular to the inboard direction DI and the outboard direction DO of the vehicle 10. For purposes of clarity, the LEDs 80 and 82, and the reflector surface portions 100, 102, 104, 106 and 108 are active lighting structures. Whereas the reflector surface of the passive reflector 32 (the reflex reflector 32) is configured and oriented such that at least a portion of light approaching the reflex reflector 32 from 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 vehicle 10, other than the headlamp structure 12, 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.
In understanding the scope of the present invention, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives. Also, the terms “part,” “section,” “portion,” “member” or “element” when used in the singular can have the dual meaning of a single part or a plurality of parts. Also as used herein to describe the above embodiment, the following directional terms “forward”, “rearward”, “above”, “downward”, “vertical”, “horizontal”, “below” and “transverse” as well as any other similar directional terms refer to those directions of a vehicle equipped with the headlamp structure. Accordingly, these terms, as utilized to describe the present invention should be interpreted relative to a vehicle equipped with the headlamp structure.
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.
The terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed.
While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. For example, the size, shape, location or orientation of the various components can be changed as needed and/or desired. Components that are shown directly connected or contacting each other can have intermediate structures disposed between them. The functions of one element can be performed by two, and vice versa. The structures and functions of one embodiment can be adopted in another embodiment. It is not necessary for all advantages to be present in a particular embodiment at the same time. Every feature which is unique from the prior art, alone or in combination with other features, also should be considered a separate description of further inventions by the applicant, including the structural and/or functional concepts embodied by such features. Thus, the foregoing descriptions of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
