BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to a component of an optical unit and, for example, to a rotating reflector rotated around a rotational axis while reflecting light emitted from a light source and to a lens unit. Further, the present invention relates to a component of an optical unit used in a vehicle headlamp and, for example, to an optical member having an optical controller for controlling light emitted from a light source. Still further, the present invention relates to a linking structure for linking connectors and, for example, to a linking structure for linking connectors for feeding power to a light source. Still further, the present invention relates to a support component for supporting the rotating reflector. Still further, the present invention relates to a method of manufacturing the optical unit. Still further, the present invention relates to a vehicle headlamp system including the optical unit.

2. Description of the Related Art

(1) In the related art, an optical unit that includes a rotating reflector rotated in one direction around a rotational axis while reflecting light emitted from a light source is proposed (see patent document 1). The rotating reflector including the optical unit is provided with a reflecting surface so that the light of the light source reflected during rotation forms a desired light distribution pattern.

(2) Apparatuses for forming a desired light distribution pattern by reflecting light emitted from a light source forward with respect to a vehicle to scan an area in front of the vehicle with the reflected light are devised recently. For example, there is known an optical unit including: a rotating reflector rotated in one direction around a rotational axis while reflecting light emitted from a light source; and a light source comprised of a light emitting device, wherein the rotating reflector is provided with a reflecting surface so that the light of the light source reflected during rotation forms a desired light distribution pattern (see patent document 2, patent document 5).

The optical unit includes: a first light source; a second light source; a rotating reflector rotated around a rotational axis while reflecting first light emitted from the first light source; and a projection lens for projecting the first light reflected by the rotating reflector in a direction of light irradiation of the optical unit. The second light source is arranged such that the emitted second light is incident on the projection lens without being reflected by the rotating reflector, and the projection lens projects the second light in the direction light irradiation.

(3) In the related art, a vehicle headlamp in which a light guiding element is provided between a light source and a condensing lens in order to condense light emitted from the light source toward a projection lens is devised (see patent document 3).

(4) In the related art, a lamp unit mounted on a vehicle, etc., in which a connector is mounted on a substrate on which the light source is mounted, is devised, the connector being connected to a feed cable for feeding power to a light source (see patent document 4).

(5) (6) The aforementioned optical unit is configured such that the rotational axis of the rotating reflector is at an angle to the light axis of the projection lens to reflect the light emitted from the light source at an angle and guiding it toward the projection lens.

Patent document 1: WO11/129105

Patent document 2: JP2018-67523

Patent document 3: JP2018-520483

Patent document 4: JP2017-37806

Patent document 5: WO15/122303

(1) The aforementioned rotating reflector can be manufactured by various methods. For example, it is possible to manufacture the rotating reflector by injection molding that uses a mold. When the rotating reflector is manufactured by injection molding that uses a mold, however, a burr may remain when the rotating reflector is released from the gate. The burr disrupts the rotational balance of a rotating body and, in particular, a rotating body like the rotating reflector. Further, when a burr is located on the outer circumference of the rotating reflector, inertia (moment of inertia) will be increased, affecting the rotational accuracy of the rotating reflector.

(2) The aforementioned optical unit includes, apart from the projection lens, a diffusion lens for changing the light path of the second light emitted from second light source and guiding it toward the projection lens.

(3) When the light emitted from the light source is incident on an area outside the optical controller of the optical member, the light may be output in an unintended direction, causing unnecessary light such as a glare.

(4) The connector mounted on the substrate is connected to another connector connected to the feed cable. If the connection is insufficient, the lighted state of the light source may be unstable, or the connectors may be disconnected.

(5) To fit the aforementioned rotating reflector to another member, it is necessary to fit the rotating reflector via a case that rotatably supports the rotating reflector. Further, if the direction of fixing the case is aligned with the rotational axis of the rotating reflector, it will be necessary to further provide a fixing part on the outer circumferential part of the case, which is larger than the diameter of the rotating reflector.

(6) The aforementioned optical unit is manufactured by assembling a plurality of components. Depending on the sequence of assembling components or the direction of assembly, the assembling steps may become complicated with the result that the efficiency of assembly is degraded, or the workload on the operator performing the assembly may be increased.

(7) When the aforementioned optical unit is used as a vehicle headlamp, a pair of left and right optical units will normally be necessary. If the layouts of main components of the optical unit are not symmetrical with respect to a vertical cross section including the longitudinal direction of the vehicle, therefore, it would be difficult to use a completely common unit for the left and right optical units.

SUMMARY OF THE INVENTION

The present invention addresses the above-described issue, and (1) an illustrative purpose thereof is to provide a novel technology for realizing a rotating reflector having a high rotational accuracy.

(2) Another illustrative purpose is to provide a novel holder for holding a plurality of lenses.

(3) Another illustrative purpose is to provide a novel technology for inhibiting occurrence of an unintended glare.

(4) Another illustrative purpose is to provide a novel technology for improving the connection reliability of the connectors.

(5) Another illustrative purpose is to provide a technology of saving the space required for the support component for rotatably supporting the rotating reflector.

(6) Another illustrative purpose is to provide a method of manufacturing an optical unit for which it is relatively easy to assemble components.

(7) Another illustrative purpose is to provide a technology for making it possible to use common components to form the optical unit.

(1) A method of manufacturing a rotating reflector according to an embodiment of the present invention is a method of manufacturing a rotating reflector including a rotating part and a blade provided around the rotating part and functioning as a reflecting surface, the method comprising: performing injection molding by using a mold in which a gate is formed more toward the rotating part than a cavity part corresponding to the blade.

Another embodiment of the present invention relates to a rotating reflector. The rotating reflector is a resin rotating reflector including: a rotating part; and a blade provided around the rotating part and functioning as a reflecting surface, wherein the rotating part has a hole in which a rotary shaft is inserted. A plurality of traces of gates are formed between the hole and the blade, and welds, in which molten resin injected from a plurality of gates converge, are formed around the hole and in the neighborhood of the traces of gates.

(2) A lens unit according to an embodiment of the present invention includes: a first lens provided on an emission side; a second lens provided on an incidence side; and a holder that holds the first lens and the second lens. The first lens overlaps the second lens in part as viewed from the emission side.

(3) An optical member according to an embodiment of the present invention includes: an optical controller that controls light incident from a back side and outputs the light from a front side; and a base part adjacent to the optical controller. The optical controller has a plurality of lens parts respectively corresponding to light emitted from a plurality of light emitting devices. The base part has a scattering part that scatters at least a portion of the light incident from the back side or the light output from the front side.

(4) A linking structure according to an embodiment of the present invention includes: a heat sink; a circuit substrate mounted on the heat sink and formed with a power feeding channel for a light source; a first connector fixed on the circuit substrate; and a guide part that guides a second connector toward the first connector when the second connector on the side of a code is connected to the first connector. The guide part is configured such that a part of the second connector enters an area between the guide part and the first connector.

(5) A support component according to an embodiment includes: a support part that rotatably supports a rotating reflector for reflecting light emitted from a light source; and fixing parts fixed to fixed parts integrated with a mounting component on which the light source is mounted. The fixing parts have positioning surfaces positioned with respect to the fixed parts. The positioning surfaces are formed to be at an angle to a rotational axis of the rotating reflector.

(6) A method of manufacturing an optical unit according to an embodiment of the present invention is a method of manufacturing an optical unit including: a light source; a mounting component on which the light source is mounted; a rotating reflector that reflects light emitted from the light source; a support component that rotatably supports the rotating reflector; a projection lens that projects reflected light reflected by the rotating reflector forward; and a lens holder that holds the projection lens. The method includes: mounting the light source on the mounting component; after the mounting, fixing the lens holder supporting the projection lens to the mounting component; and, after the fixing of the lens holder, fixing the support component supporting the rotating reflector to the mounting component.

(7) A vehicle headlamp system according to an embodiment of the present invention includes: a first optical unit provided front right in a vehicle; and a second optical unit provided front left in a vehicle. The first optical unit includes: a first light source; a first rotating reflector rotated around a rotational axis while reflecting light emitted from the first light source; and a first motor that rotates the first rotating reflector in a predetermined one direction. The second optical includes: a second light source; a second rotating reflector rotated around a rotational axis while reflecting light emitted from the second light source; and a second motor that rotates the second rotating reflector in the same predetermined one direction as a direction of rotation of the first rotating reflector. The first rotating reflector has a first reflecting surface configured to form a desired light distribution pattern by causing the light of the first light source reflected during rotation to scan an area in front of the vehicle. The second rotating reflector has a second reflecting surface configured to form a desired light distribution pattern by causing the light of the second light source reflected during rotation to scan an area in front of the vehicle. The first reflecting surface and the second reflecting surface are arranged to be horizontally symmetrical with respect to the center of the vehicle, and surface shapes of the first and second reflecting surfaces are mirror images of one another.

