Patent Grant
10914444
This application is a U.S. National Stage Application under 35 U.S.C § 371 of International Patent Application No. PCT/JP2018/016168 filed Apr. 19, 2018, which claims the benefit of priority to Japanese Patent Application No. 2017-085417 filed Apr. 24, 2017 and Japanese Patent Application No. 2017-085420 filed Apr. 24, 2017, the disclosures of all of which are hereby incorporated by reference in their entireties.
The present invention relates to a lamp unit that generates irradiation light with various light distribution patterns and a vehicular lamp system, etc. including the lamp unit.
Japanese Unexamined Patent Application Publication No. 2005-183327 (Patent Document 1) discloses a vehicular headlamp that forms a cut-off suitable for a light distribution pattern of a vehicular headlamp by shielding a part of light emitted forward from a light emitting part, by a light shielding part. In the light shielding part of the vehicular headlamp, an electro-optical element capable of realizing selective light control according to the shape of the light distribution pattern is used. Further, as for the electro-optical element, for example, a liquid crystal element is used.
Here, in the conventional vehicular headlamp described above, for example, when a general TN type liquid crystal element is used as the light shielding part, there is a disadvantage that light utilization efficiency of the light irradiated from the light emitting part is decreased.
This stems from the fact that the light transmittance of the liquid crystal element becomes approximately 35% or less due to the principle that a pair of polarizers are configured as a component of the liquid crystal element, and considering the effect of light absorption by each of the polarizers.
In a specific aspect, it is an object of the present invention to provide a technique capable of increasing the light utilization efficiency when selective light irradiation is performed using a liquid crystal element (a liquid crystal device).
[1] A lamp unit according to one aspect of the present invention includes: (a) a light source; (b) a reflective polarizing plate disposed at a position where light from the light source is incident; (c) a reflecting mirror configured to reflect a reflected light generated by the reflective polarizing plate and re-enters the reflected light to the reflective polarizing plate; (d) a liquid crystal device disposed on the light emitting surface side of the reflective polarizing plate; (e) a polarizing plate disposed on the light emitting surface side of the liquid crystal device; and (f) a lens disposed on the light emitting surface side of the polarizing plate.
[2] A vehicular lamp system according to one aspect of the present invention is a vehicular lamp system including the lamp unit described above and a control part that controls operations of the light source and the liquid crystal device of the lamp unit.
According to the above configurations, it is possible to increase the light utilization efficiency when performing selective light irradiation using a liquid crystal element (a liquid crystal device).
The light source 1 is configured to include a light emitting element such as an LED, and emits white light, for example. The number of light emitting element may be one or more. When a plurality of light emitting elements is used, it is preferable to arrange the light emitting elements in the depth direction on the paper surface of
The spread angle of the light emitted from the light source 1 is preferably as narrow as possible. Thus, it is also preferable to collimate the emitted light by arranging a lens immediately above the light emitting element such as the LED. Further, it is preferable that the center of the light beam from the light source 1 (indicated by the alternate long and short dash line in the figure) is irradiated near the center of the liquid crystal device 4. The light intensity of the light source 1 is set so that necessary and sufficient luminance can be obtained in consideration of the loss caused by the optical system.
The collimating lens 2 is disposed in front of the light emitting portion of the light source 1 and condenses the light emitted from the light source 1 to convert it into substantially parallel light.
The reflective polarizing plate 3 is, for example, a wire grid polarizing plate which transmits polarized light in a specific direction and reflects polarized light in other directions. The wire grid polarizing plate referred to here is a polarizing plate comprised by providing many thin wires which consist of metal such as aluminum on a hard substrate such as a glass substrate, and is excellent in heat resistance. As for the reflective polarizing plate 3, a reflective polarizing plate using an optical multilayer film may be used.
The liquid crystal device 4 is disposed on the light emitting surface side of the reflective polarizing plate 3 and modulates incident light to form various light distribution patterns. The liquid crystal device 4 has, for example, a plurality of light modulation regions arranged in a matrix and each light modulation region can be controlled independently. As shown in the figure, the liquid crystal device 4 is a flat plate-like device, and is arranged so that its main surface is substantially parallel to the reflective polarizing plate 3.
Further, the liquid crystal device 4 is preferably arranged with a gap (for example, a few millimeters) between the reflective polarizing plate 3 and the polarizing plate 5 without being in close contact with one another. This is because the reflective polarizing plate 3 may gain heat due to the light irradiated from the light source 1, and the heat may be transmitted to the liquid crystal device 4 to cause malfunction. By providing a gap, cooling with a fan or the like is facilitated.
Here, when an optical compensator (not shown in the figure) is to be combined with the liquid crystal device 4, the optical compensator may be directly attached to any one of the liquid crystal device 4, the reflective polarizing plate 3, or the polarizing plate 5. In this case, the optical compensator is disposed so as to be positioned between the reflective polarizing plate 3 and the polarizing plate 5.
The polarizing plate 5 is disposed on the light emitting surface side of the liquid crystal device 4, and the light (the polarized light) transmitted through the liquid crystal device 4 enters thereto. As for the polarizing plate 5, for example, a polarizing plate made of a general organic material (iodine type, dye type, etc.) can be used. Moreover, when importance is attached to heat resistance, a wire grid polarizing plate may be used. In this case, it is preferable to use a wire grid polarizing plate that suppresses surface reflection. Further, the polarizing plate 5 may be configured by stacking a polarizing plate made of an organic material and a wire grid polarizing plate.
The reflecting mirror 6 is disposed at a position facing the light incident surface side of the reflective polarizing plate 3, and when light reflected on the light incident surface of the reflective polarizing plate 3 is incident thereto, this light is reflected and re-enters the reflective polarizing plate 3. This reflecting mirror 6 is not particularly limited, and for example, a reflecting mirror configured by providing a general reflecting film (aluminum film, silver alloy film, optical multilayer film, etc.) on a substrate can be used. The reflecting state of the reflecting mirror 6 is preferably specular reflection, and therefore the surface of the reflecting mirror 6 is preferably configured to be as smooth as possible. When using resin as a base material, the mirror may be made by resin molding, etc.
Regarding the positional relationship among the reflective mirror 6, the light source 1, and the reflective polarizing plate 3, it is preferable that the direction in which the light (the light flux) of the light source 1 regularly reflected by the light incident surface (the reflective surface) of the reflective polarizing plate 3 and the normal direction of the central part of the reflecting surface of the reflective mirror 6 coincides. Further, regarding the positional relationship between the reflecting mirror 6 and the light source 1, it is preferable to arrange the reflecting mirror 6 and the light source 1 in an inclined manner so that the optical axis of the light emitted from the light source 1 and the optical axis of the light reflected by the reflecting mirror 6 are point-symmetric with respect to the normal direction of the light incident surface of the reflective polarizing plate 3 (which is also the central axis of the optical axis of the lamp unit). Further, as shown in the figure, it is most preferable that the light source 1 is disposed relatively on the upper side and the reflecting mirror 6 disposed on the lower side in the vertical direction of the lamp unit. However, the vertical relationship between the light source and the reflecting mirror may be reversed, or the light source 1 and the reflecting mirror 6 may be arranged in the left-right direction.
The projection lens 7 is disposed on the light emitting surface side of the polarizing plate 5 and condenses and projects an image formed by the light transmitted through the polarizing plate 5. This projected image becomes the irradiation light emitted by the vehicular lamp system. As for the projection lens 7, for example, a reversed projection type projector lens having a focal point at a predetermined distance can be used. In this case, a lens having a large NA (numerical aperture) is preferable. This projection lens 7 is preferably arranged so that the above-stated focal point is positioned in the liquid crystal layer (to be described later) portion of the liquid crystal device 4, but it is also possible to slightly deviate the focal point in order to prevent the projected image from becoming too sharp. Further, an image shifting function may be added to the projection lens 7.
In this lamp unit 103R, each component is arranged so that all components of light emitted from the light source 1 (including light reflected by the reflecting mirror 6) are incident on each light control function part (light control electrode forming part which is to be described later) of the liquid crystal device 4 as well as the opening portion of the reflective polarizing plate 3 and the opening portion of the projection lens 7.
Each of the first substrate 11 and the second substrate 12 is a rectangular substrate in a plan view, and is disposed to face each other. As for each substrate, for example, a transparent substrate such as a glass substrate or a plastic substrate can be used. Between the first substrate 11 and the second substrate 12, for example, a large number of spacers are uniformly distributed and these spacers keep the substrate gap at a desired size (for example, approximately a few micrometers).
The first electrode 13 is provided on one surface side of the first substrate 11. Each second electrode 14 is provided on one surface side of the second substrate 12. Each electrode is configured, for example, by appropriately patterning a transparent conductive film such as indium tin oxide (ITO). Although illustration is omitted, an insulating film may be further provided on the upper surface of each electrode. Each region where each second electrode 14 and the first electrode 13 overlap functions as a light modulation region.
The first alignment film 15 is provided on one surface side of the first substrate 11 so as to cover the first electrode 13. The second alignment film 16 is provided on one surface side of the second substrate 12 so as to cover each second electrode 14. As for each alignment film, an alignment film that regulates the alignment state of the liquid crystal layer 17 to a substantially horizontal alignment is used. Each alignment film is subjected to uniaxial alignment treatment such as rubbing treatment, and has an alignment regulating force in one direction. The direction of the alignment treatment for each alignment film is set, for example, to be substantially orthogonal to each other.
The liquid crystal layer 17 is provided between the first substrate 11 and the second substrate 12. In the present embodiment, the liquid crystal layer 17 is configured using a nematic liquid crystal material having fluidity with positive dielectric anisotropy Δε and containing an appropriate amount of a chiral material. The liquid crystal layer 17 of the present embodiment has an initial alignment determined by the alignment regulating force of the first alignment film 15 and the second alignment film 16, and when no voltage is applied, the alignment direction of the liquid crystal molecules is twisted at approximately 90° between the first substrate 11 and the second substrate 12. Further, the liquid crystal layer 17 has a pretilt angle of several degrees with respect to each substrate surface. When a voltage higher than a threshold voltage is applied between the first electrode 13 and the second electrode 14, the liquid crystal molecules in the liquid crystal layer 17 are untwisted and rise in the normal direction of the substrate.
Each wiring connected to each second electrode 14 is provided so as to extend either upward or downward in the figure. In detail, in the figure, each wiring connected to each second electrode 14 in the upper three rows extends upward, and each wiring connected to the second electrodes 14 in the lower four rows extends downward. Each wiring extends to one end side or the other end side of the second substrate 12, and is supplied with a driving voltage from an external driving device which is not shown in the figure.
In order to allow each wiring to pass through, each second electrode 14 has a different width in each row in the x direction in the figure. In detail, in the figure, with respect to the second electrodes 14 in the upper three rows, the width in the x direction becomes smaller toward the upper side along the y direction. Thereby, space for providing wiring is secured. Further, with respect to the second electrodes 14 in the lower four rows, the width in the x direction becomes smaller toward the lower side along the y direction. Thereby, space for providing wiring is secured.
Each of the second electrodes 14 is disposed so as to face the first electrode 13. By individually applying a voltage to each of the second electrodes 14 and applying a predetermined voltage to the first electrode 13, it is possible to switch between transmission and non-transmission for each light modulation region which is a region corresponding to each second electrode 14.
By adopting the liquid crystal device 4 having such a configuration and the reflective polarizing plate 3 and the polarizing plate 5 that are arranged to face each other while sandwiching the liquid crystal device 4, an image corresponding to a desired light distribution pattern can be formed, and by reversing point-symmetrically and further enlarging and projecting the image with the projection lens 7, it is possible to realize irradiation light with the desired light distribution pattern in front of the own vehicle. Specifically, as described above, it is possible to realize irradiation light in which a light irradiation region and a non-irradiation region are set according to the presence or absence of an oncoming vehicle or the like.
Hereinafter, a preferred method for manufacturing the liquid crystal device 4 included in the lamp unit will be described. A pair of glass substrates is prepared. For example, a pair of glass substrates in which a transparent conductive film such as ITO, etc. is formed in advance is used. Methods for forming the transparent conductive film include, for example, a sputtering method and a vacuum deposition method. The first electrode 13 and each of the second electrodes 14 are formed by patterning the transparent conductive film provided on the glass substrate. At this time, routing wirings is formed simultaneously (refer to
Next, the first alignment film 15 is formed on the first substrate 11, and the second alignment film 16 is formed on the second substrate 12. Specifically, a horizontal alignment film material is applied to each of the first substrate 11 and the second substrate 12 by flexographic printing, an inkjet method, or the like, and then heat treatment is performed. As for the horizontal alignment film material, for example, a main chain type horizontal alignment film material is used. The film thickness of the applied material should be approximately 500 to 800 Å (angstrom). As for the heat treatment, for example, baking is to be performed at 160 to 250° C., for 1 to 1.5 hours. Here, when the liquid crystal layer 17 is to be vertically aligned, a vertical alignment film material is used instead of the horizontal alignment film material. Further, regardless of the alignment state of the liquid crystal layer 17, an alignment film material made of an inorganic material, for example, a material where a main chain skeleton consists of siloxane bonding (Si—O—Si bonding) may be used.
Next, each of the first alignment film 15 and the second alignment film 16 is subjected to an alignment treatment. As for the alignment treatment, for example, a rubbing treatment in one direction is performed. At this time, the required pressing-in amount can be set within the range from 0.3 mm to 0.8 mm, for example. Here, when the first substrate 11 and the second substrate 12 are overlaid, the directions of the rubbing treatment are set so that the directions of the rubbing treatment on each of the first alignment film 15 and the second alignment film 16 intersects at an angle of approximately 90°. The direction of the rubbing treatment is not limited thereto and can be set in various direction.
Next, a sealing material is formed on one surface of one substrate (for example, the first substrate 11). Here, a thermosetting or photocurable sealing material (epoxy, acrylic, etc.) having high heat resistance is used. Specifically, a main seal material containing an appropriate amount of gap control material (for example, 2 to 5 wt. %) is formed on one surface of the first substrate 11. The main sealing material is formed by, for example, a screen printing method or a dispenser printing method. The diameter of the gap control material included in the main seal material is selected according to the layer thickness set value of the liquid crystal layer 17, and is approximately 4 μm, for example.
Further, a gap control material is dispersed, or a rib material is formed on one surface of the other substrate (for example, the second substrate 12). In the case of using a gap control material, for example, a plastic ball having a diameter of 4 μm is sprayed by a dry-type gap material spraying device. In the case of using a rib material, a resin film is patterned.
Next, the first substrate 11 and the second substrate 12 are overlapped with each electrode formation surface facing each other, and while applying a constant pressure with a press or the like, the main sealing material is cured by heat treatment or ultraviolet irradiation. For example, when a thermosetting sealing material is used, heat treatment is performed at 150° C.
Next, a liquid crystal layer 17 is formed by filling the gap between the first substrate 11 and the second substrate 12 with a liquid crystal material. The liquid crystal material is filled by, for example, a vacuum injection method. A liquid crystal material having a positive dielectric anisotropy Δε and a refractive index anisotropy Δn of, for example, approximately 0.15 can be used. Here, note that a small amount of chiral material may be added to the liquid crystal material. The filling of the liquid crystal material may also be performed by an ODF method. Here, when the liquid crystal layer 17 is vertically aligned, a liquid crystal material having a negative dielectric anisotropy is used.
After the liquid crystal layer 17 is formed, the inlet port is sealed with an end seal material. As for the end seal material, for example, an ultraviolet curable resin is used. Thus, the liquid crystal device 4 is completed.
In Embodiment 2 as well, each component is arranged so that a part of the center point of the light emitted from the light source 1 passes through the reflective polarizing plate 3 and is irradiated on the substantial center of the main surface of the liquid crystal device 4, and furthermore, a part of the light emitted from the light source 1 is regularly reflected by the reflective polarizing plate 3 to enter the reflecting mirror 6 and the central point of the reflected light when the light is reflected is irradiated to the substantial center of the main surface of the liquid crystal device 4.
As for the phase difference plate 8, for example, a broadband ½ wavelength plate (λ/2 plate), ¼ wavelength plate (λ/4 plate), ¾ wavelength plate (3λ/4 plate) or the like can be used. When a ¼ wavelength plate is used as the phase difference plate 8, it is preferable that the slow axis direction is arranged at an angle of approximately 45° with respect to the polarization axis of the reflective polarizing plate 3, and when a ½ wavelength plate is used, it is preferable that the slow axis direction is arranged at an angle of approximately 22.5° with respect to the polarization axis of the reflective polarizing plate 3. With such an arrangement, for example, a linearly polarized light in a predetermined direction of reflected light created by the reflective polarizing plate 3 passes through the ¼ wavelength plate once to become a circularly polarized light, then the light is reflected by the reflecting mirror 6 to pass through the ¼ wavelength plate again to become a linearly polarized light whose polarization direction is rotated by 90° from the predetermined direction, and re-enters the reflective polarizing plate 3, so that most of the light component passes through the reflective polarizing plate 3.
When generalized, the frequency in which light emitted from the light source 1 passes through the phase difference plate 8 becomes 2n (n: a natural number). And the phase difference given by the phase difference plate 8 is, for example, λ/2n−λ/4 (n: a natural number), where λ is the wavelength of the light. The polarization direction of the light which is reflected by the reflective polarizing plate 3, then reflected by the reflective mirror 6 and re-enters the reflective polarizing plate 3 is changed by (180n−90)° (n: an integral number) by the phase difference plate 8.
Here, in the lamp unit 123R shown in
The phase difference plate 9 is disposed on the light incident surface side of the reflective polarizing plate 3, and gives a phase difference to incident light. As for the position where the phase difference plate 9 is disposed, for example, it is preferably disposed in close contact with the light incident surface side of the reflective polarizing plate 3 as illustrated in the figure, but in principle, it may be disposed anywhere on the optical path between the light source 1 and the reflective polarizing plate 3. As for the phase difference plate 9, for example, a broadband ½ wavelength plate (λ/2 plate), ¼ wavelength plate (λ/4 plate), ¾ wavelength plate (3λ/4 plate), or the like can be used. In this case, polycarbonate (PC), cycloolefin (COP) or the like can be used as the material.
When a ¼ wavelength plate is used as the phase difference plate 9, it is preferable that the slow axis direction is arranged at an angle of approximately 45° with respect to the polarization axis of the reflective polarizing plate 3, and when a ½ wavelength plate is used, it is preferable that the slow axis direction is arranged at an angle of approximately 22.5° with respect to the polarization axis of the reflective polarizing plate 3. With such an arrangement, for example, a linearly polarized light in a predetermined direction of reflected light created by the reflective polarizing plate 3 passes through the ¼ wavelength plate once to become a circularly polarized light, then the light is reflected by the reflecting mirror 6 to pass through the ¼ wavelength plate again to become a linearly polarized light whose polarization direction is rotated by 90° from the predetermined direction, and re-enters the reflective polarizing plate 3, so that most of the light components pass through the reflective polarizing plate 3.
When generalized, the frequency in which light emitted from the light source 1 passes through the phase difference plate 9 becomes (2n−1) (n: a natural number). And the phase difference given by the phase difference plate 9 is, for example, λ/2n−λ/4 (n: a natural number), where λ is the wavelength of the light. The polarization direction of the light which is reflected by the reflective polarizing plate 3, then reflected by the reflective mirror 6 and re-enters the reflective polarizing plate 3 is changed by (180n−90)° (n: an integral number) by the phase difference plate 9.
In this lamp unit 133R, each component is arranged so that all components of light emitted from the light source 1 (including light reflected by the reflecting mirror 6) are incident on each light control function part (light control electrode forming part which is to be described later) of the liquid crystal device 4 as well as the opening portion of the reflective polarizing plate 3 and the opening portion of the projection lens 7.
In Embodiment 5 as well, each component is arranged so that a part of the center point of the light emitted from the light source 1 passes through the reflective polarizing plate 3 and the phase difference plate 9, and is irradiated on the substantial center of the main surface of the liquid crystal device 4, and furthermore, a part of the light emitted from the light source 1 is regularly reflected by the reflective polarizing plate 3 to enter the reflecting mirror 6, and the central point of the reflected light when the light is reflected is irradiated to the substantial center of the main surface of the liquid crystal device 4.
Here, in the lamp unit 153R shown in
According to each embodiment as described above, since the reflected light from the reflective polarizing plate of the lamp unit is reflected by the reflecting mirror and re-enters the reflective polarizing plate, the light utilization efficiency can be improved. Therefore, it is possible to increase the light utilization efficiency in the vehicular lamp system that performs selective light irradiation using liquid crystal elements. Further, when the polarization direction is adjusted by using a phase difference plate, the light utilization efficiency can further be increased.
It should be noted that this invention is not limited to the subject matter of the foregoing embodiments, and can be implemented by being variously modified within the scope of the present invention as defined by the appended claims. For example, in the above-described embodiments, a normally black mode is assumed as the operation mode of the liquid crystal device, but the operation mode may also be a normally white mode. Further, the liquid crystal device is exemplified by a liquid crystal layer having a twisted alignment (TN alignment), but is not limited thereto. A liquid crystal device of any operation mode is acceptable as long as it is capable of controlling the transmissive or non-transmissive state of partial region of light. Further, an optical compensator such as a C plate may be appropriately combined with the liquid crystal device.
Further, the above embodiments describe the cases where the present invention is applied to a vehicular lamp system that performs selective light irradiation according to the presence or absence of an oncoming vehicle or the like in front of the vehicle, but the application of this invention is not limited thereto. For example, the present invention can be applied to a vehicular lamp system that switches light irradiation according to the turning direction of the vehicle, or a vehicular lamp system that variably controls the optical axis direction of the headlamp according to the inclination angle of the vehicle in the front-rear direction. Further, the present invention can be applied to a vehicular lamp system that switches between a high beam and a low beam in a headlamp without depending on a mechanical operation part.
Further, the lamp unit according to the present invention can be used not only for use in vehicles but also for various uses as a lighting device capable of generating various light distribution patterns.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2017-085417 | Apr 2017 | JP | national |
| 2017-085420 | Apr 2017 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2018/016168 | 4/19/2018 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2018/198939 | 11/1/2018 | WO | A |
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| 20160139328 | Hikmet | May 2016 | A1 |
| 20190360653 | Toko | Nov 2019 | A1 |
| 20200011501 | Kunii | Jan 2020 | A1 |
| Number | Date | Country |
|---|---|---|
| H09-146092 | Jun 1997 | JP |
| 2005-183327 | Jul 2005 | JP |
| 2006-147377 | Jun 2006 | JP |
| 2010-250326 | Nov 2010 | JP |
| 9533224 | Dec 1995 | WO |
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| 2011091557 | Aug 2011 | WO |
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| 2018198939 | Nov 2018 | WO |
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| Number | Date | Country | |
|---|---|---|---|
| 20200217472 A1 | Jul 2020 | US |
