KR102264129B1 - Vehicle lens assembply, method for assembling the same and lighting apparatus for vehicle having the assembly - Google Patents

Abstract

The lens assembly for a vehicle according to the present invention includes a lens that transmits light emitted from a light source and exits to the outside, and a bracket for fixing and accommodating the lens,
The bracket may include a frame having an opening through which the emitted light passes and surrounding the lens; a first flange extending in a direction in which the light is emitted near an edge of the frame; and a second flange extending in a direction opposite to a direction in which the light is emitted near an edge of the frame and forming a predetermined angle with the first flange.
At this time, a bent portion is formed in the second flange to overlap the first flange, and the first flange and the second flange are overlapped between the bent portion of the second flange and the first flange. A welding portion is formed for fixedly coupling the.

Description

A vehicle lens assembly, an assembly method thereof, and a vehicle lighting apparatus having the assembly TECHNICAL FIELD

The present invention relates to a lighting device for a vehicle, and more particularly, to a vehicle lens assembly capable of accurately forming a light distribution pattern of emitted light close to a desired target value, and a method for assembling the same.

The vehicle is provided with a lighting device having a lighting function for easily identifying an object located around the vehicle during night driving and a signal function for notifying other vehicles or road users of the driving state of the vehicle. For example, a headlamp and a fog lamp serve as a lighting function, and a turn indicator, a taillight, a brake light, and a side marker serve as a signal function.

In general, in a vehicle lighting device that irradiates light to a specific irradiation area, it is required to irradiate light of uniform illuminance to the irradiation area. Light irradiation of such uniform illuminance can be realized, for example, by using a lens optical system including a collimation lens and a micro-lens array (MLA).

However, in order to obtain illumination light with high uniformity in this type of lighting device, it is necessary to provide each member at an accurate position in the case. In particular, in this type of lighting device, it is necessary to accurately incident light with a high degree of parallelism to the microlens array. In particular, in a type of vehicle lamp requiring design and assembly precision, slight errors in the position and/or orientation between the light source and the collimation lens and between the collimation lens and the micro lens array, for example, an error of several millimeters per 100 millimeters of the optical axis distance Even if , the resulting light distribution pattern shows a significant difference from the designed target light distribution pattern.

In the related art, the lighting device disclosed in Japanese Patent Application Laid-Open No. 2007-91119A includes a first spacer between a collimation lens and a circuit board and a second spacer between the collimation lens and the fly's eye lens to construct a lens optical system. are doing At this time, the case accommodating the lens optical system is composed of a cylindrical case having an inward flange at the distal end, each component of the lens optical system is inserted into the case through the base-side opening, and each component is inserted into the inward flange and the circuit board Disclosed is a configuration for supporting each other in a case by pressing between them.

However, even in this prior art, errors may still occur during processing of each member or assembling between members compared to design, and as described above, a light distribution pattern is greatly affected by even a minute error.

Japanese Patent Application Laid-Open No. 2007-91119 (published on 12/04/2007)

The technical problem to be achieved by the present invention in consideration of these problems is to provide a lighting device for a vehicle capable of accurately forming a target light distribution pattern by precisely setting the position and/or direction of each member without degrading assembling property will do

The technical problems of the present invention are not limited to the technical problems mentioned above, and other technical problems not mentioned will be clearly understood by those skilled in the art from the following description.

A vehicle lens assembly according to an embodiment of the present invention for achieving the above technical problem includes a lens that transmits light emitted from a light source and exits to the outside, and a bracket for fixing and accommodating the lens,

The bracket may include a frame having an opening through which the emitted light passes and surrounding the lens; a first flange extending in a direction in which the light is emitted near an edge of the frame; and a second flange extending in a direction opposite to the direction in which the light is emitted near the edge of the frame and forming a predetermined angle with the first flange,

A bent portion is formed on the second flange to overlap the first flange, and the first flange and the second flange are fixedly coupled to each other at a position overlapped between the bent portion of the second flange and the first flange. A weld is formed for

According to one aspect of the present invention, the lens is a micro-lens array unit.

According to an aspect of the present invention, the bracket further includes a flap extending in a direction opposite to the direction in which the light is emitted beyond the first and second flanges on the first and second flanges.

According to an aspect of the present invention, the bracket further includes a position protrusion formed at a plurality of positions along an edge of the frame and protruding into the frame, wherein the position protrusion is configured to fix the lens in the bracket. It is pressed against the edge surface of the lens.

According to an aspect of the present invention, the second flange protrudes inwardly of the second flange, and when the bent portion of the second flange overlaps the first flange, the lens is caught by the edge of the lens so that the lens is It includes a stopper protrusion that prevents it from being separated from the bracket.

According to an aspect of the present invention, the stopper protrusion has a semi-open structure that is partially opened in a direction opposite to the direction in which the light is emitted.

According to an aspect of the present invention, the lens and the frame have a rectangular shape, and the predetermined angle formed by the first flange and the second flange is a right angle.

According to an aspect of the present invention, the first flange is formed on the upper and lower edges of the frame, and the second flange is formed on the left and right edges of the frame.

According to an aspect of the present invention, the second flange is bent inwardly with respect to the frame so that the overlapping area of the bent portion of the second flange and the first flange is from a small state to a state in which the overlapping area is large. have.

A lighting device for a vehicle according to an embodiment of the present invention for achieving the above technical problem includes: a light source; a first lens that transmits the light emitted from the light source; a second lens for emitting the transmitted light to a light irradiation area; and a bracket for fixing and accommodating the second lens,

The bracket may include a frame having an opening through which the emitted light passes and enclosing the lens; a first flange extending in a direction opposite to a direction in which the light is emitted near an edge of the frame; and a second flange extending in a direction in which the light is emitted near the edge of the frame and forming a predetermined angle with the first flange,

A bent portion is formed in the second flange to overlap the first flange, and the first flange and the second flange are fixedly coupled to each other at a position overlapped between the bent portion of the second flange and the first flange. A weld is formed for

According to the vehicle lighting device according to the present invention, a target light distribution pattern can be accurately formed by precisely setting the position and direction of each member of the vehicle lighting device.

In addition, since the relative position and direction between the light source and the collimation lens and between the collimation lens and the micro lens array unit can be accurately determined while checking the light distribution pattern obtained in the actual intermediate step, the match between the designed light distribution pattern and the finally obtained light distribution pattern can be practically guaranteed.

In addition, since the relative position and direction are determined and then fixed through welding, a problem in which the determined position or direction is unintentionally changed later can also be prevented in advance.

1 is a perspective view illustrating a heat sink block according to an embodiment of the present invention.
FIG. 2 is a perspective view illustrating a state in which a plurality of vehicle lighting devices are mounted on the heat sink block of FIG. 1 .
3 is an exploded perspective view illustrating a sequence of arranging a vehicle lighting device on a mounting surface of a heat sink block.
4 is a perspective view illustrating a state in which a circuit board is mounted on a mounting surface of a heat sink block.
5 is a perspective view showing a state before combining the lens bracket and the collimation lens.
6 is a perspective view showing a state after combining the lens bracket and the collimation lens.
7 is a perspective view showing a state before the lens bracket and the PCB bracket are combined.
8 is a perspective view showing a state after the lens bracket and the PCB bracket are combined.
9 and 10 are perspective views viewed from different directions before the micro lens array unit and the MLA bracket are combined.
11 is an exploded perspective view illustrating a detailed configuration of a micro lens array unit.
12 is a view showing a process of fixing the micro lens array unit in the MLA bracket by bending the second flange inward after receiving the micro lens array unit in the MLA bracket.
13 is a perspective view showing the micro lens array unit after it is mounted on the MLA bracket.
14 is a perspective view showing a state after the MLA bracket and the lens bracket are combined.
15 is a view showing an active alignment process as a whole according to an embodiment of the present invention.
16 is a longitudinal cross-sectional view of the vehicle lighting device of FIG.
17 is a schematic diagram illustrating a path through which light irradiated from a light source is emitted to the outside in a lighting device for a vehicle.
18 is a flowchart illustrating a method of assembling a lighting device for a vehicle according to an embodiment of the present invention.
19 is a flowchart illustrating step S120 of FIG. 18 in more detail.

Advantages and features of the present invention and methods of achieving them will become apparent with reference to the embodiments described below in detail in conjunction with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but will be implemented in a variety of different forms, and only these embodiments allow the disclosure of the present invention to be complete, and common knowledge in the technical field to which the present invention belongs It is provided to fully inform the possessor of the scope of the invention, and the present invention is only defined by the scope of the claims. Like reference numerals refer to like elements throughout.

Unless otherwise defined, all terms (including technical and scientific terms) used herein may be used with the meaning commonly understood by those of ordinary skill in the art to which the present invention belongs. In addition, terms defined in a commonly used dictionary are not to be interpreted ideally or excessively unless clearly defined in particular.

The terminology used herein is for the purpose of describing the embodiments and is not intended to limit the present invention. As used herein, the singular also includes the plural unless specifically stated otherwise in the phrase. As used herein, “comprises” and/or “comprising” does not exclude the presence or addition of one or more other components in addition to the stated components.

Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

1 is a perspective view illustrating a base member 1 according to an embodiment of the present invention, and FIG. 2 is a view in which a plurality of vehicle lighting devices 100: 100a, 100b, 100c are mounted on the base member 1 It is a perspective view shown.

The base member 1 on which the plurality of vehicle lighting devices 100 are mounted may generally have a heat sink function, but is not limited thereto. However, in the following description of the present invention, the base member 1 will be described as an example of a heat sink block having a heat sink function.

The heat sink block 1 may be formed of a material with high thermal conductivity, such as metal or thermally conductive resin, and absorbs heat generated from the light source of the vehicle lighting device 100 , particularly the vehicle lighting device 100 , to the outside. can be released The heat sink block 1 is provided with a plurality of mounting surfaces 2: 2a to 2f for mounting the vehicle lighting device 100 .

In this way, the directions in which the plurality of vehicle lighting devices 100 seated on the mounting surfaces 2a to 2f irradiate light may completely coincide, but in order to form various light distribution patterns, each of the vehicle lighting devices 100a, 100b, 100c) may be designed to have a different light irradiation direction. For example, the overall light distribution pattern may be obtained by first determining the light irradiation direction of the central lighting apparatus 100b and then determining the light irradiation direction of the peripheral lighting apparatuses 100a and 100c.

Although it has been described that the lighting device 100 is mounted on only three mounting surfaces among a total of six mounting surfaces in FIG. 2 , it may be mounted on all six mounting surfaces, and the remaining three mounting surfaces are different from the lighting device 100 . A type of lighting device (eg, a typical reflector type lighting device) may be disposed.

3 is an exploded perspective view showing a sequence of disposing the vehicle lighting device 100 on the mounting surface 2 of the heat sink block 1 . As shown, as components included in the vehicle lighting device 100, the circuit board 10, the PCB bracket 20, the lens bracket 40, the collimation lens 50, the micro lens array unit 70 and In the order of arrangement of the MLA bracket 80 , it may be mounted on the mounting surface 2 by being aligned with respect to the optical axis Ax.

Specifically, looking at the assembly sequence of the vehicle lighting device 100 , first, the circuit board 10 is fixed to the mounting surface 2 by the PCB bracket 20 . The circuit board 10 has a substantially rectangular shape and the light source 11 is disposed thereon. The light source 11 is preferably a semiconductor light emitting device such as an LED, but is not limited thereto, and it is also possible to use a bulb type or other type of light source. In addition, a connector for electrically connecting to a power supply circuit (not shown) is provided on the circuit board 10 . Such a circuit board is generally composed of an insulating member, but is not limited thereto.

4 is a perspective view illustrating the circuit board 10 and the PCB bracket 20 mounted on the mounting surface 2 of the heat sink block 1 . First, after the circuit board 10 is disposed on the mounting surface 2 of the heat sink block 1 as shown in FIG. 1 , the PCB bracket 20 is overlapped and disposed on the circuit board 10 . Then, the circuit board 10 and the PCB bracket 20 are fixedly fastened on the mounting surface 2 by fasteners 21a and 21b such as bolts, pins, and snap-fits. These fasteners (21a, 21b) may be installed at at least two or more points, and separately positioning means (22a, 22b) (eg, a protrusion fitted into a hole) for holding only a position without a fastening function may be additionally provided. may be

At this time, since the light source 11 is provided on the circuit board 10 , an opening 23 is formed in the center of the PCB bracket 20 so that the light emitted from the light source 11 is not blocked. In addition, the PCB bracket 20 is provided with a plurality of flaps (flaps) (25a to 25d) extending in the optical axis (Ax) direction from four edges. These flaps 25a to 25d are used for coupling with the lens assembly 60 to be described later, and when an external force is applied, some degree of elastic deformation or plastic deformation may occur. In the description of the present invention, the optical axis (Ax) direction means a direction in which the light emitted from the light source 11 is irradiated to the outside through at least one lens or lens array, and in this sense, the vehicle lighting device 100 It will be used in the same sense as the direction in which the light is emitted from, that is, the light output direction.

When the fixing of the circuit board 10 is completed in FIG. 4 , as shown in FIG. 5 , the lens bracket 40 and the collimation lens 50 are combined to complete the lens assembly 60 . Here, the collimation lens 50 (collimation lens) may be made of, for example, a light-transmitting resin molded article, and may be implemented as a spherical lens, an aspherical lens, a Fresnel lens, etc. by type. Light emitted from the light source 11 passes through the collimation lens 50 and is converted into substantially parallel light. Although this converted light may not be perfectly collimated light, the light passing through the collimation lens 50 is at least aligned to improve parallelism.

The lens bracket 40 to which the collimation lens 50 is mounted has an opening 46 through which light can pass in the central portion, and a plurality of flaps 45a to 45d extending from four edges in the light emission direction. includes The plurality of flaps 45a to 45d are used for coupling with the MLA bracket to be described later, and when an external force is applied, some degree of elastic deformation or plastic deformation may occur.

Cantilevers 41a to 41d are formed on the central side of the plurality of flaps 45a to 45d, with a fixed end positioned farther from the light source 11 and a free end positioned closer to the light source. In addition, protrusions 42a to 42d protruding inward are formed on the inner surfaces of the cantilevers 41a to 41d. Therefore, when the collimation lens 50 is inserted into the lens bracket 40 in a direction opposite to the light output direction, the collimation lens 50 is fixed in the lens bracket 40 by the protrusions 42a to 42d. is accommodated and deviation in the light exit direction is prevented.

Specifically, the protrusions 42a to 42d include guide portions 43a to 43d for guiding the collimation lens 50 to be easily inserted into the lens bracket 40, and the vertices of the guide portions 43a to 43d. connected to the guide portions 43a to 43d, and includes stepped portions 44a to 44d that prevent the collimation lens 50 from being separated from the lens bracket 40 after being inserted into the lens bracket 40 do.

As such, when the collimation lens 50 is inserted into the lens bracket 40 and crosses the protrusions 42a to 42d, the cantilevers 41a to 41d generate elastic deformation while the collimation lens 50 is easily inserted. can be In addition, when the collimation lens 50 enters the lens bracket 40 completely beyond the protrusions 42a to 42d, the cantilevers 41a to 41d return to their original positions, and in this case, the protrusions 42a to 42d. The collimation lens 50 is not separated from the lens bracket 40 by the stepped portions 44a to 44d (see FIG. 6 ).

5 and 6 described above, the collimation lens 50 is mounted on the lens bracket 40 in the opposite direction to the light output direction, but as another embodiment, the collimation lens 50 is the lens in the light output direction. It may be mounted on the bracket 40 . In the other embodiment, after disposing the collimation lens 50 in the finger members (not shown) projecting rearwardly from the four edges of the lens bracket 40 instead of the protrusions 42a to 42d, the finger members The collimation lens 50 may be fixed in such a way that the finger member is bent inwardly so as to surround the collimation lens 50 .

The lens assembly 60 assembled as shown in FIG. 6 is coupled to the PCB bracket 20 already assembled in the heat sink block 1 . At this time, specifically, the lens bracket 40 and the PCB bracket 20 of the lens assembly 60 are coupled to each other. 7 is a perspective view showing a state before the lens assembly 60 and the PCB bracket 20 are combined, and FIG. 8 is a perspective view showing the state after the lens assembly 60 and the PCB bracket 20 are combined.

As described above, the PCB bracket 20 includes flaps 25a to 25d extending in the light output direction, and the lens bracket 40 includes flaps 45a to 45d extending in the light output direction. include When the lens bracket 40 and the PCB bracket 20 are coupled, the flaps 25a to 25d overlap to surround the flaps 45a to 45d. As another embodiment, the flaps 25a to 25d of the PCB bracket 20 extend in the light output direction, but the flaps 45a to 45d of the lens bracket 40 may be formed in the opposite direction to the light output direction. Do. In this case, it is also possible to configure the flap of the PCB bracket 20 to surround the flap of the lens bracket 40 or, conversely, to configure the flap of the lens bracket 40 to surround the flap of the PCB bracket 20 . However, in the following for convenience of explanation, the PCB bracket 20 and the lens bracket 40 include flaps 25a to 25d and 45a to 45d that are formed to extend in the light output direction, and the PCB bracket 20 is The description will be made on the assumption that the flaps 25a to 25d surround the flaps 45a to 45d of the lens bracket.

At this time, the flaps 25a to 25d of the PCB bracket 20 each have an extension portion 26a to 26d extending in the light output direction, and an outwardly inclined outward direction than the extension portion while being connected to the extension portion. and inclined portions 27a to 27d. The outwardly inclined portions 27a to 27d facilitate the flaps 25a to 25d of the PCB bracket 20 to wrap the flaps 45a to 45d of the lens bracket 40 .

Referring to FIG. 8 showing the form after the lens assembly 60 and the PCB bracket 20 are combined, the flaps 25a to 25d of the PCB bracket 20 are the flaps 45a to 45d of the lens bracket 40. There is a region that overlaps while being wrapped in contact with each other. Specifically, the flaps 25a to 25d of the PCB bracket 20 may be coupled to the cantilevers 41a to 41d formed on the flaps 45a to 45d of the lens bracket 40 . Since these cantilevers 41a to 41d can be pressed by the flaps 25a to 25d while having elasticity during such coupling, basic positioning between the flaps 25a to 25d and the flaps 45a to 45d is facilitated.

As described above, although once coupled between the lens bracket 40 and the PCB bracket 20, it is not completely fixed without movement between the two. The PCB bracket 20 is fixedly coupled to the heat sink block 1, but between the PCB bracket 20 and the lens bracket 40, as the flaps are fitted between the flaps, they are coupled by elastic or plastic deformation of the flaps. When an external force is applied, the lens bracket 40 may move within a certain range.

In the present invention, a desired desired light distribution baton can be more precisely obtained by using such a movement. For example, in a state in which the light source 11 is turned on and the PCB bracket 20 and the lens bracket 40 are combined, the lens bracket 40 is jigd in 3 degrees of freedom (x, y, z axes). ), a desired light distribution pattern can be obtained by adjusting the light distribution pattern formed on the screen while moving. In the present invention, this adjustment process is defined as active alignment. In the case of the active alignment, since the approximate direction is determined in advance, only a minute movement is sufficient and there is no need to apply a large movement. However, since the light distribution pattern is an intermediate light distribution pattern made by a combination of only the light source 11 and the collimation lens 50, the active alignment is performed by comparing the intermediate light distribution pattern actually obtained with the target intermediate light distribution pattern. will be able

When a desired light distribution pattern is obtained through the above process, it is necessary to fix the lens bracket 40 so that it does not move any more as it is. Therefore, according to an embodiment of the present invention, in the overlapping positions 30a to 30d between the flaps 45a to 45d of the lens bracket 40 and the flaps 25a to 25d of the PCB bracket 20, the lens bracket ( 40) and a welding portion for fixing and coupling the PCB bracket 20 is formed. The welding portion may be formed at a plurality of points among the four overlapping positions 30a to 30d. Accordingly, among the four overlapping positions 30a to 30d, the formation of the weld portion may be omitted at a point not suitable for welding due to space constraints. Such a weld is preferably exemplified by laser welding, but other welding methods such as arc welding, electric resistance welding, plasma welding and the like are not excluded.

By forming the welding part at the overlapping position between the flaps in this way, the position and direction of the collimation lens 50 can be set in an accurate direction indicating the intermediate light distribution pattern desired by the user.

9 and 10 are perspective views viewed from different directions before the micro lens array unit 70 and the MLA bracket 80 are combined. The micro-lens array unit (MLA) 70 may be mounted on the MLA bracket 80 in the light output direction.

The micro lens array unit 70 is also a kind of optical lens and is also called a fly-eye lens, and has a special shape in which a plurality of microscopic lenses are arranged on a two-dimensional plane.

The micro lens array unit 70 is generally manufactured by stacking several layers. For example, as shown in FIG. 11 , in the micro lens array unit 70 , two glass wafers 72 and 73 are disposed in the center, and incident surfaces are formed on both sides of the glass wafers 72 and 73, respectively. The light-transmitting polymer 71 and the light-transmitting polymer 74 forming the emitting surface are disposed so that a total of four layers may be stacked. A very large number of microlenses 75 are two-dimensionally repeatedly formed on the incident surface of the polymer 71 and/or the exit surface of the polymer 74 . Due to the configuration of the micro lens array unit 70 , light incident from the collimation lens 50 (approximately parallel light) is emitted at positions overlapping each other, thereby providing light with improved uniformity for a specific irradiation area.

The MLA bracket 80 for mounting the micro-lens array unit 70 has an opening 82 through which the light emitted from the micro-lens array unit 70 is transmitted, specifically, the edge of the micro-lens array unit 70 . a frame 81 surrounding the frame 81, and first flanges 83a to 83d extending in a direction opposite to the direction in which the light is emitted near the edge of the frame 81, and the frame 81 and second flanges 84a to 84d extending in a direction opposite to the direction in which the light is emitted near the edge and forming a predetermined angle (eg, 90 degrees) with the first flanges 83a to 83d. In addition, the MLA bracket 80 further includes flaps 85a to 85d extending in a direction opposite to the direction in which the light is emitted beyond the first flanges 83a to 83d and the second flanges 84a to 84d. .

Here, the second flanges 84a to 84d have bent portions 86a to 86d bent substantially parallel to the first flanges 83a to 83d so as to overlap the first flanges 83a to 83d. is formed 12, after the micro lens array unit 70 is accommodated in the MLA bracket 80 (S1), the second flanges 84a to 84d and some (85a, 85c) or all of the flaps 85a to 85d ) is bent inward to fix the micro lens array unit 70 in the MLA bracket 80 (S2). Through the process of FIG. 12, the second flanges 84a to 84d have a small overlapping area with the bent portions 86a to 86d of the second flanges 84a to 84d and the first flanges 83a to 83d. The overlapping area is changed to a large state.

After the micro lens array unit 70 is fixed to the MLA bracket 80 in this way, at least a portion of the overlapping regions 91a to 91d between the bent portions 86a to 86d and the first flanges 83a to 83d. A welding portion for fixedly coupling the first flanges 83a to 83d and the second flanges 84a to 84d is formed. Such a weld is preferably exemplified by laser welding, but other welding methods such as arc welding, electric resistance welding, and plasma welding are not excluded.

In addition, the MLA bracket 80 is formed at a plurality of positions along the edge of the frame 81 and further includes position protrusions 87a to 87f protruding into the frame 81 (see FIGS. 9 and 10). . These position protrusions 87a to 87f, after bending the second flanges 84a to 84d inward as shown in FIG. 12 to fix the micro lens array unit 70 to the MLA bracket 80, the unit 70 It is pressed against the edge surface 77 having this.

And, the second flanges 84a to 84d protrude inward of the second flanges 84a to 84d, and bend the second flanges 84a to 84d inward as shown in FIG. When overlapping with the first flanges 83a to 83d, stopper protrusions 88a to 88a to seat the unit 70 in the MLA bracket 80 by being caught on the edge surface 77 of the micro lens array unit 70 . 88d). In order to reduce the thickness of the MLA bracket 80, that is, the size in the light output direction, the stopper protrusions 88a to 88d may be formed in a semi-open structure that is at least partially opened toward the opposite direction to the light output direction. .

As a result, the MLA bracket 80, as shown in FIG. 12, after receiving the micro lens array unit 70 in the MLA bracket 80, when bending the second flanges 86a to 86d inward, the position protrusion ( 87a to 87f) and the stopper projections 88a to 88d are primarily fixed. Next, the micro lens array unit 70 is finally seated in the MLA bracket 80 by forming welds in the overlapping regions 91a to 91d between the bent portions 86a to 86d and the first flanges 83a to 83d. (see FIG. 13). Such a weld is preferably exemplified by laser welding, but other welding methods such as arc welding, electric resistance welding, and plasma welding are not excluded.

The MLA assembly 90 assembled as shown in FIG. 13 is coupled to the lens bracket 40 already assembled to the PCB bracket 20 . As described above, since the micro lens array (MLA) unit is also a type of optical lens, the MLA assembly also belongs to the vehicle lens assembly.

Specifically, the MLA bracket 80 and the lens bracket 40 are coupled to each other. 14 is a perspective view showing the shape after coupling between the MLA bracket 80 and the lens bracket 40 .

As described above, the lens bracket 40 includes flaps 45a to 45d extending in the light output direction, and the MLA bracket 80 includes flaps 85a to 45d extending in the opposite direction to the light output direction. 85d). Upon coupling between the MLA bracket 80 and the lens bracket 40, the flaps 85a to 85d overlap to surround the other flaps 45a to 45d. However, the present invention is not limited thereto, and the wrapping relationship between the flaps may be reversed.

At this time, the flaps 45a to 45d formed on the lens bracket 40 include extension parts 47a to 47d extending in the light output direction, and an inward slope connected to the extension part and inclined inward than the extension part. parts 48a to 48d. The inwardly inclined portions 48a to 48d guide the flaps 85a to 85d to easily wrap the other flaps 45a to 45d.

As such, although it is coupled between the MLA bracket 80 and the lens bracket 40, it is not completely fixed without movement between the two. Although the MLA bracket 80 is fixedly coupled to the lens bracket 40, an external force is generated between the MLA bracket 80 and the lens bracket 40 because they are coupled by elastic or plastic deformation of the flaps according to the fitting between the flaps. When applied, the MLA bracket 80 can move in a certain range.

By using this movement, the desired and desired final light distribution baton can be obtained more precisely. For example, in a state in which the light source 11 is turned on and the MLA bracket 80 and the lens bracket 40 are combined, the MLA bracket 80 is moved in three degrees of freedom (x, y, z axes) by a jig. By active alignment, which controls the light distribution pattern formed on the screen while moving, a desired final light distribution pattern can be obtained.

When a desired light distribution pattern is obtained through the above process, it is necessary to fix the lens bracket 40 so that it does not move any more as it is. Therefore, according to an embodiment of the present invention, the MLA bracket 80 at the overlapping positions 35a to 35d between the flaps 85a to 85d of the MLA bracket 80 and the flaps 45a to 45d of the lens bracket 40. A welding portion for fixing and coupling the lens bracket 40 and the lens bracket 40 is formed. The welding portion may be formed at a plurality of points among the four overlapping positions 35a to 35d. Such a weld is preferably exemplified by laser welding, but other welding methods such as arc welding, electric resistance welding, and plasma welding are not excluded. By forming the weld at the overlapping position between the flaps in this way, the micro lens array unit 70 can be directed in the correct direction indicating the final light distribution pattern desired by the user.

15 is a view showing overall active alignment processes according to an embodiment of the present invention. As described above, active alignment may be applied when firstly coupling the lens assembly 60 to the PCB bracket 20 , and secondarily, the MLA assembly 90 to the lens bracket 40 of the lens assembly 60 . Another active sort can be performed when combining .

Through the active alignment twice as described above, the directions of both the collimation lens 50 and the micro lens array unit 70 can be precisely set, but the active alignment does not necessarily have to be performed twice. For example, when the lens assembly 60 is coupled to the PCB bracket 20, it is simply fixed without active alignment, and only when the MLA assembly 90 is coupled to the lens bracket 40 of the lens assembly 60, active alignment is performed. may be applied, or conversely, active alignment may be applied only when the lens assembly 60 is coupled to the PCB bracket 20 . This can be applied when the number of active alignments is reduced to reduce the complexity and time required of the process. However, if it is a condition in which only one active alignment is to be applied, it may be more efficient to relatively apply it when the MLA assembly 90 is coupled to the lens bracket 40 . This is because the final light distribution pattern may be more sensitive to a directional error between the collimation lens 50 and the micro lens array unit 70 .

16 is a longitudinal cross-sectional view of the vehicle lighting device 100 of FIG. 14 cut in a longitudinal direction (a direction parallel to the x-z plane). Referring to FIG. 16 , a first weld is formed in regions 35a to 35d where the flaps 85a to 85c of the MLA bracket 80 overlap between the flaps 45a to 45d of the lens bracket 40, and the PCB bracket ( A second weld is formed in the regions 30a to 30d where the flaps 25a to 25c of 20 are overlapped between the flaps 45a to 45d of the lens bracket 40 . Accordingly, in a preferred embodiment of the present invention, the first welding portion is located farther from the light source than the second welding portion.

17 is a schematic diagram illustrating a path through which the light irradiated from the light source 11 is emitted to the outside in the vehicle lighting apparatus 100 .

The light 12 emitted from the light source 11 is converted into substantially parallel light 13 while passing through the collimation lens 50 , and the converted light 13 passes through the micro lens array unit 70 . Light 14 with improved uniformity is emitted. This is because, due to the configuration of the microlens array unit 70, the parallel-converted light 13 is emitted to a position overlapping each other, so that the uniformity of brightness is improved within the range of a specific irradiation area.

According to the vehicle lighting apparatus 100 of the present invention, the direction and/or position of the collimation lens 50 with respect to the light source 11 is precisely set to a target value, and the micro lens for the collimation lens 50 The direction and/or position of the array unit 70 may also be precisely set to a target value. Accordingly, it is possible to provide a more precise and accurate light distribution baton compared to the prior art in which a desired light distribution pattern cannot be precisely obtained due to design tolerances or assembly errors.

Such an active alignment scheme proposed in the present invention is an individual vehicle lighting device 100 as well as a plurality of vehicle lighting devices 100a, 100b, 100c in one heatsink block 1 as shown in FIG. 2 . It can also be applied comprehensively.

For example, by applying the active alignment scheme to the central lighting device 100b, the light irradiation direction is first determined, and then the active alignment scheme is sequentially applied to the surrounding lighting devices 100a and 100c. By doing so, it is also possible to precisely set up to the entire light distribution pattern formed by the plurality of lighting devices 100a, 100b, and 100c together. Accordingly, the alignment between the MLA bracket 80 and the lens bracket 40 according to the fixed coupling relationship between the flaps 85a to 85d and the flaps 45a to 45d, and between the flaps 45a to 45d and the flaps 25a to 25d Alignment between the lens bracket 40 and the PCB bracket 20 according to the fixed coupling relationship may be formed differently depending on the point at which the vehicle lighting devices 100a, 100b, 100c are mounted in the heat sink block 1 will be.

18 is a flowchart illustrating a method of assembling the lighting device 100 for a vehicle according to an embodiment of the present invention.

First, as shown in FIG. 1 , a base member or a heat sink block 1 having at least one mounting surface 2a to 2f is provided ( S110 ). In addition, by assembling the collimation lens 50 and the lens bracket 40 to create the lens assembly 60 as shown in FIG. 6 (S115), and assembling the micro lens array unit 70 and the MLA bracket 80 13, the same MLA assembly 90 is generated (S120). The above steps S110, S115, and S120 do not necessarily have to be processed in this order, and some or all of the order may be changed. Among them, the process of generating the MLA assembly 90 in S120 will be described later in more detail with reference to FIG. 19 .

Next, using the PCB bracket 20, the circuit board 10 on which the light source 11 is installed as shown in FIG. 4 is mounted on the base member 1 (S125). The PCB bracket 20 includes flaps 25a to 25d extending from edges of the PCB bracket 20 in the light output direction (Ax in FIG. 3 ).

In this way, after the PCB bracket 20 and the circuit board 10 are mounted on the base member 1, the lens bracket 40 is coupled to the PCB bracket 20 (S130). Here, the lens bracket 40 includes flaps 45a to 45d extending from the edges of the lens bracket 40 in the light output direction (Ax in FIG. 3 ). Since the collimation lens 50 and the lens bracket 40 are already assembled in S115 to provide the lens assembly 60, it can also be seen that the lens assembly 60 is coupled to the PCB bracket 20 through this.

Specifically, when the step S130 is coupled, the flaps 25a to 25d of the PCB bracket 20 overlap to surround the flaps 45a to 45d of the lens bracket 40 (see FIG. 8 ).

In such a state that the flaps are overlapped, the primary active alignment is performed between the PCB bracket 20 and the lens bracket 40 (S135). In this primary active alignment, in order to obtain a desired light distribution pattern (intermediate light distribution pattern) in a state in which the light source 11 is turned on as described above with respect to FIG. 15, the lens bracket 40 is previously fixed to the PCB bracket 20 It is the process of controlling the smile while moving about it.

If a desired light distribution pattern is obtained through this primary active alignment, the overlapping positions 30a to 30d of the flaps 25a to 25d of the PCB bracket 20 and the flaps 45a to 45d of the lens bracket 40 are A first welding portion for fixedly coupling the flaps 25a to 25d and the flaps 45a to 45d is formed (S140).

Next, the MLA bracket 80 is coupled to the lens bracket 40 already fixed by the first welding part (S145). Here, the MLA bracket 80 includes flaps 85a to 85d extending from the edges of the MLA bracket 80 in a direction opposite to the light emission direction (Ax in FIG. 3 ). Since the micro lens array unit 70 and the MLA bracket 80 are already assembled in S120 to provide the MLA assembly 90 , it can also be seen that the MLA assembly 90 is coupled to the lens bracket 40 through this.

Specifically, when the step S145 is coupled, the flaps 85a to 85d of the MLA bracket 80 overlap to surround the flaps 45a to 45d of the lens bracket 40 (see FIG. 14 ).

In such a state that the flaps are overlapped, secondary active alignment is performed between the MLA bracket 80 and the lens bracket 40 (S150). This secondary active alignment is performed by moving the MLA bracket 80 with respect to the pre-fixed lens bracket 40 to obtain a desired final light distribution pattern in a state in which the light source 11 is turned on as described above with respect to FIG. It is a process of control.

If a desired light distribution pattern is obtained through this secondary active alignment, the overlapping positions (35a to 35d) of the flaps (85a to 85d) of the MLA bracket (80) and the flaps (45a to 45d) of the lens bracket (40) A second welding portion for fixedly coupling the flaps 85a to 85d and the flaps 45a to 45d is formed ( S155 ).

As described above, the first welding portion and the second welding portion may be formed by laser welding, but the present invention is not limited thereto. In addition, as described above, it is not always necessary to perform two active alignments together, and it is also possible to perform only the primary active alignment or only the secondary active alignment.

19 is a flowchart illustrating in more detail the step S120 of FIG. 18 , that is, assembling the MLA assembly (a type of lens assembly for a vehicle).

First, a micro lens array unit 70, which is a special type of optical lens, is prepared (S121), and an MLA bracket 80 for fixedly accommodating the micro lens array unit 70 is provided (S123).

The MLA bracket 80 includes an opening 82 through which light emitted from the light source 11 passes, a frame 81 for enclosing the micro lens array unit 70 , and an edge of the frame 81 . First flanges 83a to 83d extending in a direction opposite to the light output direction Ax nearby, and first flanges 83a to 83d extending in the opposite direction near an edge of the frame 81 ) and second flanges 84a to 84d forming a predetermined angle (eg, 90˚), and a bent portion bent from the second flanges 84a to 84d to overlap with the first flanges 83a to 83d ( 86a to 86d). In this case, the first flanges 83a to 83d may be formed at upper and lower edges of the frame 81 , and the second flanges 84a to 84d may be formed at left and right edges of the frame 81 .

Next, as shown in S1 of FIG. 12 , the micro lens array unit 70 is disposed in the frame 81 of the MLA bracket 80 in the light output direction Ax (S125).

Thereafter, as shown in S2 of FIG. 12 , the overlapping area of the bent portions 86a to 86d and the first flanges 83a to 83d is changed from a small state to a state in which the overlapping area is large. The second flanges 84a to 84d are bent inward (S127). At this time, the flaps 85a to 85d extending from the MLA bracket 80 in a direction opposite to the light output direction Ax may also be bent.

After bending the second flanges 84a to 84d inward, the overlapping positions 91a to 91d between the bent portions 86a to 86d of the second flanges 84a to 84d and the first flanges 83a to 83d. ) to form a weld (S129). The welding portion may be formed by laser welding, but is not limited thereto.

By forming such a weld, not only the first flanges 83a to 83d and the second flanges 84a to 84d are fixed to each other, but also the micro lens array unit 70 is permanently in the MLA bracket 80 as well. is fixed In this way, in order to securely fix the micro lens array unit 70 in the MLA bracket 80, the MLA bracket 80 is additionally provided with the position protrusions 87a to 87f as described above in FIGS. 9, 10 and 13 . ) and the stopper protrusions 88a to 88d may be further included.

Although the embodiments of the present invention have been described above with reference to the accompanying drawings, those of ordinary skill in the art to which the present invention pertains can realize that the present invention can be embodied in other specific forms without changing its technical spirit or essential features. you will be able to understand Therefore, it should be understood that the embodiments described above are illustrative in all respects and not restrictive.

1: Heatsink block 2: Mounting surface
10: circuit board 11: light source
20: PCB bracket 25: Flap of PCB bracket
40: lens bracket 45: flap of the lens bracket
50: collimation lens 60: lens assembly
70: micro lens array unit 80: MLA bracket
85: flap of MLA bracket 90: MLA assembly
100: vehicle lighting device

Claims (15)

A lens assembly for a vehicle comprising a lens for transmitting light emitted from a light source and emitting to the outside, and a bracket for fixing and receiving the lens,
The bracket is
a frame having an opening through which the emitted light passes and surrounding the lens;
a first flange extending in a direction opposite to a direction in which the light is emitted near an edge of the frame; and
and a second flange extending in a direction opposite to the direction in which the light is emitted near the edge of the frame and forming a predetermined angle with the first flange,
The second flange is formed with a bent bent portion to be overlapped with the first flange,
A welding portion for fixing the first flange and the second flange to be fixedly coupled to the overlapping position between the bent portion of the second flange and the first flange is formed, a vehicle lens assembly. According to claim 1,
The lens is a micro-lens array unit, a vehicle lens assembly. According to claim 1, wherein the bracket,
The lens assembly for a vehicle further comprising a flap extending in a direction opposite to a direction in which the light is emitted beyond the first and second flanges. According to claim 1,
The bracket further comprises a position protrusion formed at a plurality of positions along the edge of the frame and protruding into the frame,
The position protrusion is pressed against an edge surface of the lens to fix the lens in the bracket. According to claim 1, wherein the second flange is
and a stopper protrusion that protrudes inward of the second flange and catches the edge of the lens when the bent portion of the second flange overlaps the first flange to prevent the lens from being separated from the bracket. lens assembly. The method of claim 5, wherein the stopper protrusion is
A lens assembly for a vehicle, having a semi-open structure partially opened in a direction opposite to a direction in which the light is emitted. According to claim 1,
The lens and the frame have a rectangular shape,
The predetermined angle formed by the first flange and the second flange is a right angle. 8. The method of claim 7,
The first flange is formed on upper and lower edges of the frame, and the second flange is formed on left and right edges of the frame. 9. The method of claim 8,
The second flange is bent inward with respect to the frame so that the overlapping area of the bent portion of the second flange and the first flange is from a small state to a state in which the overlapping area is large. light source; a first lens that transmits the light emitted from the light source; a second lens for emitting the transmitted light to a light irradiation area; and a bracket for fixing and accommodating the second lens,
The first lens is a lens that improves the parallelism of the emitted light, the second lens is a lens in which a plurality of micro-sized lenses are arranged,
The bracket is
a frame having an opening through which the emitted light passes and surrounding the second lens;
a first flange extending in a direction opposite to a direction in which the light is emitted near an edge of the frame; and
a second flange extending in a direction opposite to the direction in which the light is emitted near the edge of the frame and forming a predetermined angle with the first flange,
The second flange is formed with a bent bent portion to be overlapped with the first flange,
A welding portion for fixedly coupling the first flange and the second flange is formed at a position overlapping between the bent portion of the second flange and the first flange. A method of assembling a lens assembly for a vehicle comprising a lens that transmits light emitted from a light source and exits to the outside, and a bracket for fixing and accommodating the lens,
An opening through which the light emitted from the light source passes, a frame for enclosing the lens, and a first flange extending near an edge of the frame in a direction opposite to the direction in which the light is emitted, near the edge of the frame providing the bracket including a second flange extending in the opposite direction and forming a predetermined angle with the first flange, and a bent portion bent from the second flange to overlap the first flange;
disposing the lens on the frame of the bracket in a direction in which the light is emitted; and
bending the second flange inward so that the overlapping area between the bent portion and the first flange is changed from a small overlapping area to a large overlapping area; and
after bending the second flange inward, forming a welding portion at a position overlapped between the bent portion and the first flange to fix the lens in the bracket. 12. The method of claim 11,
The lens is a micro-lens array unit, the method of assembling a lens assembly for a vehicle. The method of claim 11, wherein the bracket comprises:
The method of assembling a lens assembly for a vehicle further comprising a flap extending in a direction opposite to a direction in which the light is emitted beyond the first and second flanges. 12. The method of claim 11,
The method of assembling a lens assembly for a vehicle, wherein the first flange is formed on upper and lower edges of the frame, and the second flange is formed on left and right edges of the frame. 12. The method of claim 11,
The method of assembling a lens assembly for a vehicle, wherein the welding portion is formed by laser welding.

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