DE102022101928A1 - Optical solid body made of a solid transparent material, light module with such a solid optical body and motor vehicle lighting device with such a light module - Google Patents

Abstract

The invention relates to a solid optical body (10) made of a solid, transparent material for use in a light module (12) of a motor vehicle lighting device (14). The solid optics body (10) comprises a light coupling section (16) via which light from a light source (18) of the light module (12) can be coupled into the solid optics body (10), and a light coupling section (22) via which at least a part of the light coupled into the solid optics (10) is decoupled from the solid optics (10), so that the decoupled light is used to generate at least part of a light distribution of the motor vehicle lighting device (14) in front of the motor vehicle. Furthermore, the solid optics (10) has an optically active layer (24) arranged in the beam path between the coupling-in section (16) and the coupling-out section (22), which is designed to change incident light. It is proposed that the optically effective layer (24) is formed inside the solid optics body (10).

Description

The present invention relates to a solid optical body made of a solid, transparent material for use in a light module of a motor vehicle lighting device. The solid optics comprises a light coupling section, via which light from a light source of the light module can be coupled into the solid optics body, and a decoupling section, via which at least part of the light coupled into the solid optics body is decoupled from the solid optics body, so that the decoupled light is used to generate at least part of a light distribution of the motor vehicle lighting device in front of the motor vehicle. The solid optics body also has an optically effective layer, which is arranged in the beam path between the coupling-in section and the coupling-out section, and changes the incident light.

Furthermore, the invention also relates to a light module of a motor vehicle lighting device, with a light source and a solid optics body. The light source is designed and arranged and aligned with respect to the solid optics body such that it emits light in a main emission direction in the direction of a coupling section of the solid optics body. The solid optics body is designed to change light coupled into the solid optics body via the coupling section by means of an optically active layer, so that light coupled out via a coupling-out section of the solid optics body generates at least part of a light distribution of the motor vehicle lighting device in front of the motor vehicle.

Finally, the invention relates to a motor vehicle lighting device with a housing that has a light exit opening closed by a cover pane and a light module inside the housing that projects light in front of the motor vehicle to generate a light distribution of the motor vehicle lighting device or part of it.

Such light modules are known in different embodiments from the prior art. They have the advantage that they can be designed to be particularly small. In addition, they are inexpensive to manufacture, since alignment and adjustment of various components of the light module relative to one another (e.g. primary optics or reflector relative to the mirror screen) can be omitted due to the one-piece optic solid body.

From the EP 1 357 333 A2 For example, a light module of the type mentioned at the outset is known for use in a motor vehicle headlight. The solid optics body used has a coupling section on its underside, which is opposite a light source of the light module in the form of an LED. Furthermore, the solid optics has a primary optics section with a reflection surface, which is arranged opposite the coupling section on the upper side of the solid optics. An optically active layer in the form of a horizontal mirror diaphragm is arranged on the underside of the solid optics body, next to the coupling section. An intermediate image, which is generated in an intermediate image plane at a front edge of the mirror cover, is imaged by a projection lens of the light module as a shielded light distribution of the motor vehicle headlight in front of the vehicle. The projection lens is formed separately from the solid optics body and is arranged downstream of the decoupling section of the solid optics body in the beam path. In this case, both the primary optics section and the mirror diaphragm are formed on an outer boundary surface of the solid optics body.

With the known optics solid bodies can only one type of light distribution, for example. As in the EP 1 357 333 A2 a low beam distribution, can be generated. Another type of light distribution, for example a high beam distribution, must be generated by a different light module of the lighting device. This other light module is usually designed as a conventional reflection or projection module without a solid optic body. The disadvantage here is that when the lighting device is installed, the various light modules for generating the low beam and the high beam must be aligned and adjusted relative to one another. This is complex and expensive. In addition, the two light modules take up a relatively large amount of space. The result is relatively large motor vehicle lighting devices.

In addition, the non-optical areas of the solid optics body, on which the primary optics section and/or the mirror diaphragm are formed on the outer boundary surface of the solid optics body, can not be used for other purposes, e.g. as a fastening section for fastening the solid optics body in the light module or for fastening the light module in the housing of the motor vehicle lighting device.

Proceeding from the prior art described, the object of the present invention is to design a solid optics body of the type mentioned at the outset and thus also a light module and a complete motor vehicle lighting device of the type mentioned at the outset to be as small as possible. In addition, light modules that can be used multifunctionally in as small a space as possible should be realized by the invention. Finally, an internal delimitation of optical and non-optical areas are made possible within the optics solid body in order to be able to use the non-optical areas for other purposes.

To solve this problem, a solid optic body with the features of claim 1 is proposed. In particular, based on the solid optics body of the type mentioned at the outset, it is proposed that the optically effective layer be formed inside the solid optics body.

Unlike in the prior art, where the optically effective layer (diaphragm section, e.g. mirror diaphragm, or primary optics section, e.g. reflector) is arranged or formed outside on an outer boundary surface of the solid optics body, the optically effective layer in the present invention is formed or arranged within the solid optics body. In other words, the optically effective layer is surrounded on all sides by the material of the solid optics body. This opens up completely new possibilities with regard to a multifunctional optical solid body that is as small as possible, which will be explained in detail below.

With the invention, it is possible to produce an optically effective layer within a solid optics body to implement a diaphragm, specifically also a mirror diaphragm, a spectral converter, a filter or the like. This enables a very compact design of multi-function light modules. Furthermore, an internal delimitation of optical and non-optical areas of the solid optics can also be realized by the internal optically effective layer. The non-optical areas are available for other uses, for example as a fastening section. Overall, the outlay for installation can be reduced, since only a solid optics body with an integrated aperture section and/or integrated primary optics section is required, instead of providing the aperture section and/or primary optics section as separate parts on an outer boundary surface of the solid optics body, and the functional integration can be increased by the partial or complete separation of light paths.

The full body of the optics is made of a solid, transparent material, for example glass or plastic, made of PC or PMMI in particular due to the good temperature stability. But PMMA could also be used as a material if the temperatures inside the solid optics body can be limited. A light-emitting semiconductor element, in particular an LED (light-emitting diode) or an LD (laser diode) is preferably used as the light source. Of course, several light sources can also be assigned to a single solid optics body and couple light into the solid optics body simultaneously, individually or in groups.

The light source emits light in a main emission direction. The main direction of emission can be aligned parallel, at an angle or perpendicular to an optical axis of the solid optics body. When aligned slightly obliquely or parallel to the optical axis, the light coupled into the solid optics can be directed directly in the direction of the optically effective layer of the solid optics and does not have to be deflected on the way there by the solid optics. In the case of an alignment at a sharp angle or perpendicular to the optical axis, it may be necessary for the solid optics to have a primary optics section which is designed to bundle at least part of the light coupled into the solid optics body and/or to deflect it in the direction of the optically effective layer of the solid optics body. The primary optics section can include a reflection surface, which is formed on the outside on an outer boundary surface of the solid optics body, preferably opposite the coupling section. Alternatively, the primary optics section can also be formed or arranged by an optically effective layer, in particular a reflective layer, within the meaning of the present invention inside the solid optics body. It is therefore conceivable that the solid optics body has a plurality of optically effective layers. These can have the same or different functions.

The motor vehicle lighting device in which the solid optical body according to the invention can be used is not limited to a specific type of lighting device and can be designed, for example, as a headlight to generate a driving light (e.g. low beam and/or high beam), as a fog lamp to generate a fog light or as a cornering light to generate a cornering light or cornering light.

A large number of different configurations and/or functions of the optically active layer are conceivable. For example, the optically effective layer can take on the function of a screen section, in particular a light-shading screen or a mirror screen, given a corresponding configuration. The invention makes it possible, among other things, to implement the function of a diaphragm, in particular a mirror diaphragm, within the solid optics body without having to rely on reflection at an outer boundary surface of the solid optics body.

The areas of the optics solid body behind the aperture, which are shaded by the optically effective layer, ie reaches no light and which can therefore be referred to as non-optical areas, can take on non-optical tasks, for example serve as a fastening section for fastening the solid optics body or the light module in the lighting device or the like. This would not be possible in the prior art since the diaphragm section and/or the primary optics section would be arranged on the outside on the interface of the solid optics body.

In order to arrange a screen inside the solid optics body, a film or a coating with absorbent and/or reflective properties can be introduced into the material of the solid optics body as an intermediate step during the production of the solid optics body, e.g. by means of a multi-layer injection molding process or a multi-component multi-layer process. In particular, the foil or the coating can be applied to a partial solid optics body produced in a previous production step and then sprayed over or overmolded with a further layer of the material of the solid optics body in a subsequent step.

The film has a light-reflecting and/or absorbing surface at least on a side facing the coupling-in section. An absorbing surface can absorb at least part of the incident light and thus shade part of the injected light and thus form a desired light distribution. The absorbing surface is, for example, matt black. For example, it would be conceivable to generate a light-dark boundary in this way at the transition between an illuminated area of a light distribution and a shaded area of the light distribution. The light-dark boundary can have a horizontal or nearly horizontal (asymmetrical) progression in order to produce a shielded light distribution, for example a fog light or low beam or a part thereof. Likewise, the light-dark boundary can have a vertical or almost vertical profile, for example to generate a partial high beam in which areas of the light distribution in front of the motor vehicle in which other road users have been detected are shaded in order to avoid dazzling them.

A reflective surface of the foil can reflect incident light so that it is not lost but can contribute to the generation of the light distribution. As a result, a light distribution with a shaded area and an illuminated area can be generated, which includes the light that has passed the mirror aperture on the one hand and the light reflected by the aperture in the light exit direction of the light module on the other. A particularly efficient light distribution with a light-dark boundary can also be generated in this way.

Furthermore, the film could also be designed to be partially transparent, i.e. part of the light striking the optically active layer passes through the film and another part of the light is absorbed and/or reflected by the film. This has the advantage that the part of the light transmitted through the foil can reach the shaded area of a shielded light distribution, in particular above a light-dark boundary, and can be used there within the framework of the light distribution for realizing special lighting tasks. In this way, for example, overhead lighting of a low beam can be implemented above the light-dark boundary. A low beam distribution must also meet certain legal requirements above the light-dark boundary with regard to the locations of maximum and minimum brightness values and the values themselves. This requirement can be met by the transmitted light.

Instead of inserting a foil in an intermediate step in the production of the solid optics body, it would also be conceivable to apply a coating, e.g. in the form of a selective metallization, to the previously produced solid optics part in the intermediate step between two injection molding cycles, and then to spray or encapsulate this coating with another layer of the material of the solid optics body. The coating can, for example, be a color (e.g. matt black) that can be sprayed onto the previously manufactured partial optic solid body in order to absorb at least part of the incident light. The coating in the form of a metallization can be applied, for example, by means of sputtering or vapor deposition to the solid partial optics body produced in a previous production step. The metallization layer comprises a metal, preferably with good reflection properties, in particular aluminum (Al), silver (Ag), chromium (Cr) or the like.

The optically effective layer introduced into the solid optics body, e.g. the film or coating, is preferably designed and shaped in such a way that it generates an intermediate image in an intermediate image plane, which can be imaged by secondary or projection optics of the light module, e.g. a projection lens, to generate a resulting light distribution in front of the motor vehicle. In particular, the optically effective layer is designed and shaped so that it generates an intermediate image in the intermediate image plane, which is used by the secondary or projection optics to generate a dimmed light distribution (e.g. low beam, fog light, cornering light) or one Partial high beam can be mapped in front of the motor vehicle. The intermediate image plane is preferably inside the solid optics body. In this case, an edge, in particular a front edge of a diaphragm running along an optical axis of the solid optics body, can be imaged by the secondary or projection optics as the light-dark boundary of the light distribution. The secondary or projection optics are arranged downstream of the optically effective layer in the beam path.

The secondary or projection optics are preferably configured separately from the solid optics body. A separate projection or secondary optic has the advantage that the refraction of the light required for the projection of the intermediate image can be divided over several light passage surfaces (light exit surface of the decoupling section of the solid optics body, light entry surface of the projection lens, light exit surface of the projection lens). As a result, the resulting light distribution can be generated with greater precision and there is a greater degree of design freedom.

The secondary or projection optics has a particularly short focal length as a result of the novel solid optics body with an integrated optically effective layer, which can be, for example, in the range of just 50 mm (+/- 20 mm).

However, it would also be conceivable for the secondary or projection optics to be formed by the decoupling section as an integral part of the solid optics body. For example, a light exit surface of the decoupling section, in particular a light exit surface convex outward, takes on the function of the secondary or projection optics and forms the intermediate image from the intermediate image plane as a light distribution in front of the motor vehicle. Even if this embodiment would result in less precision of the light distribution and/or less design freedom, this embodiment can be advantageous in certain circumstances. In this way, for example, a particularly compact, highly integrated optic solid body can be realized, which enables the construction of particularly small light modules. As a result, installation space in the motor vehicle headlight and costs can be saved. In addition, there are completely new creative freedoms with regard to the design of the lighting devices.

In addition, it would be conceivable to design the optically effective layer in such a way that it completely or partially converts light from a first spectrum that is coupled into the solid optics body into light from another spectrum, i.e. changes the color of the light. This can be realized, for example, in that the optically active layer only reflects the light components of a specific frequency spectrum and absorbs or transmits other spectral components. In this context, it would be conceivable, for example, for the optically effective layer to have a specific coloration on its surface facing the coupling section, for example red, green or blue, in order to specifically change the coloration of the light of the resulting light distribution. The coloring can be applied, for example, by means of spraying or sputtering paint onto a previously produced partial solid optics body and then sprayed over or overmolded with material of the solid optics body. Changing the color of the light may be necessary if the light source used only emits light of a specific color (e.g. white light with a slight yellow tint) that cannot be easily changed at the light source itself. Here, the optically effective layer offers an easily realizable option for color correction of the light of the resulting light distribution. In this way, the individual wishes of motor vehicle manufacturers for the color of the light for their vehicles (some manufacturers prefer a greenish white light for the headlight functions, while others prefer a bluish or yellowish white light) can be accommodated easily and inexpensively in this way.

Since only part of the light coupled into the solid body of the optics hits the optically active layer and can therefore be changed spectrally or in color at all, the color of the light can only be changed slightly by the optically active layer with spectral-changing properties. As a result, for example, daylight white light (over 5,300 K) can be converted into warm white light (under 3,300 K) with a relatively high proportion of yellow or into cold white light (approx. 7,000-9,000 K) with a higher proportion of blue and/or green.

Alternatively or additionally, it would also be conceivable to design the optically effective layer in such a way that it has light-filtering properties. In this case, only incident light of a specific frequency spectrum is reflected. The remaining frequency spectrum of the light is transmitted or absorbed. The optically effective layer in the form of an optical filter can have a simple color coating or more complex alternatives, e.g. an interference filter. The interference filter can comprise one or more diffraction structures lying one on top of the other. Alternatively or additionally, however, the interference filter can also include a plurality of partially transparent metallic mirror layers (e.g.: silver, aluminum). The optically effective layer in the form of an optical filter can be applied, for example, by means of sputtering, spraying or vapor deposition onto a previously produced partial solid optics body and then sprayed over or overmolded with the material of the solid optics body.

The optically effective layer inside the solid optics body can also be designed as a totally reflecting layer. This can be formed inside the solid optics body, for example, by creating at least one internal volume of the solid optics body with a different refractive index compared to the rest of the solid optics body, so that an internal boundary surface results between the internal volume with the different refractive index and the rest of the solid optics body, which totally or partially reflects the incident light. Total reflection at internal interfaces occurs in particular when the light propagates in a volume (or medium) with a higher refractive index and a volume (or medium) with a lower refractive index is beyond the interface. In the opposite direction, at best, partial reflections occur, in which individual polarization directions of the light are sometimes strongly influenced. The volumes with different refractive indices can be formed, for example, during the production of the solid optics body as part of a multi-layer injection molding process, in that transparent material with different refractive indices is used in the various successive production steps to produce the corresponding volumes. The material of the at least one internal volume with the different refractive index preferably has the same coloring as the rest of the solid optics body. However, it would also be conceivable for the material of the at least one internal volume to have a different coloration.

The optically effective layer can be flat and lie on an optical axis of the solid optics body or run parallel to the optical axis of the solid optics body. In the case of a lighting device installed as intended in a motor vehicle and a light module with a solid optic body arranged therein as intended, the optically effective layer preferably has an extent which essentially runs in a horizontal plane. In this way, dimmed light distributions with a light-dark boundary with a strictly horizontal progression, for example a fog light, a cornering light or a cornering light or a basic low beam light, can be generated.

According to a preferred embodiment, however, it is proposed that the optically effective layer - in the case of a lighting device installed as intended in a motor vehicle and a light module with solid optics arranged therein as intended - has a first flat section which extends from one side of the solid optics body in the direction of a vertical center plane of the solid optics body, in particular in the direction of the optical axis of the solid optics body. The horizontal section is located on its own traffic side of the vertical median plane. After the projection by the secondary or projection optics, the flat section serves to generate a horizontal section of an asymmetrical light-dark boundary, for example a low beam according to ECE or a low beam spotlight. The horizontal section of the light-dark boundary is preferably arranged in front of the motor vehicle on the oncoming traffic side, in particular on the oncoming traffic lane. The first section of the optically effective layer is followed by a sloping section which—in a view opposite to the light exit direction of the light from the solid optic body—can be flat, curved or even stepped. The sloping section is located on the opposite traffic side of the vertical median plane. After the projection by the secondary or projection optics, the falling section serves to generate a rising section of an asymmetrical light-dark boundary, for example a low beam according to the ECE standard or a low beam spotlight. The rising section of the light-dark boundary is preferably arranged in front of the motor vehicle on the traffic side of the vehicle, in particular at the edge of the traffic side of the vehicle and/or on the vehicle's own road.

According to an advantageous development of the invention, it is proposed that the internal optically effective layer of the solid optics separates a first area of the solid optics, to which a first light source of the motor vehicle lighting device is assigned, from a second area of the solid optics, to which a second light source of the lighting device is assigned. Of course, more than one light source can also be assigned to the first and second areas of the solid optics body. The two areas of the solid optics body preferably consist of the same solid, optically transparent material, in particular transparent material with the same refractive index. The optically effective layer can be completely flat or—as described above—asymmetrical with a sloping section and lies on or runs parallel to an optical axis of the solid optics body or to the optical axes of the first area and the second area of the solid optics body. The optically effective layer is advantageously designed as a screen that shades impinging light, in particular as a mirror screen that reflects impinging light completely or partially in the direction of the decoupling section of the solid optics body.

The first area of the solid optics can be used, for example, to generate a first light distribution of the lighting device or a part thereof, and the second area to generate a second Be formed light distribution or part thereof. The first light distribution is, for example, a dimmed light distribution with a horizontal or almost horizontal (asymmetrical) light-dark boundary, for example low beam or fog light. The first light distribution preferably meets the legal requirements for low beam or fog light alone. However, it would also be conceivable for the first light distribution to only meet the legal requirements for low beam or fog light in interaction with another light distribution that is generated by another area of the solid optics body or by another light module.

The second light distribution illuminates, for example, an area of the light distribution above the light-dark boundary and, together with the shielded light distribution of the first area of the solid optics, generates a high beam distribution. This preferably alone meets the legal requirements for high beam. However, it would also be conceivable for the second light distribution to only meet the legal requirements for high beams in conjunction with another light distribution that is generated by another area of the solid optics body or by another light module.

Each of the areas of the solid optics body has a coupling-in section facing the corresponding light source and a coupling-out section. It is also conceivable that the two decoupling sections of the first and second area of the solid optics body are combined to form a common decoupling section or are formed by a single common decoupling section. The common decoupling section of the solid optics body can be designed as a lens, for example. In particular, the common decoupling section has a single light exit surface curved convexly outward.

With the present invention, it is possible for the first time to implement a low beam module and a high beam module with a common solid optics body. With the previously known solid optics, where the aperture section and/or the primary optics section (e.g. the mirror aperture and/or the reflection surface) were only formed or arranged on the outer boundary surfaces of the solid optics body, only either a low beam module or a high beam module could be implemented. With the present invention, therefore, further miniaturization of the light modules for motor vehicle lighting devices is promoted. At the same time, the manufacture of the light modules is considerably simplified and accelerated, since the solid optics body has all components including the low beam module, the optically effective layer (e.g. in the form of a screen, in particular a mirror screen) and the high beam module. These components of the optics solid body are already aligned relative to each other and attached to each other. A separate assembly and adjustment of these components can thus be omitted.

If the optically effective layer is designed to be partially transparent and has light-transmitting properties, the transmitted part of the light can get from the first area of the solid optics body into the second area of the solid optics body and exit via its decoupling section and participate in the generation of the first light distribution. This transmitted light can then be used, for example, to generate overhead lighting above the light-dark limit of a dimmed light distribution.

• 1 ein erfindungsgemäßes Lichtmodul für eine Kraftfahrzeugbeleuchtungseinrichtung gemäß einem ersten Ausführungsbeispiel, mit einem erfindungsgemäßen Optik-Vollkörper in einem vertikalen Längsschnitt;
• 2 das Lichtmodul aus 1 in einem horizontalen Längsschnitt;
• 3 ein erfindungsgemäßes Lichtmodul für eine Kraftfahrzeugbeleuchtungseinrichtung gemäß einem zweiten Ausführungsbeispiel, mit einem erfindungsgemäßen Optik-Vollkörper in einem vertikalen Längsschnitt;
• 4 das Lichtmodul aus 3 in einem horizontalen Längsschnitt;
• 5 ein erfindungsgemäßes Lichtmodul für eine Kraftfahrzeugbeleuchtungseinrichtung gemäß einem dritten Ausführungsbeispiel, mit mehreren erfindungsgemäßen Optik-Vollkörpern in einem horizontalen Längsschnitt;
• 6 ein erfindungsgemäßes Lichtmodul für eine Kraftfahrzeugbeleuchtungseinrichtung gemäß einem vierten Ausführungsbeispiel, mit mehreren erfindungsgemäßen Optik-Vollkörpern in einem horizontalen Längsschnitt;
• 7 eine Ansicht von vorne in einen Optik-Vollkörper nach einem der 1 bis 4 entgegen einer Lichtaustrittsrichtung;
• 8 eine erste alternative Ausgestaltung einer optisch wirksamen Schicht im Inneren eines Optik-Vollkörpers nach 7;
• 9 eine zweite alternative Ausgestaltung einer optisch wirksamen Schicht im Inneren eines Optik-Vollkörpers nach 7;
• 10 eine erfindungsgemäße Kraftfahrzeugbeleuchtungseinrichtung gemäß einem bevorzugten Ausführungsbeispiel;
• 11 ein erfindungsgemäßes Lichtmodul für eine Kraftfahrzeugbeleuchtungseinrichtung gemäß einem fünften Ausführungsbeispiel, mit einem erfindungsgemäßen Optik-Vollkörper in einem vertikalen Längsschnitt;
• 12 ein erfindungsgemäßes Lichtmodul für eine Kraftfahrzeugbeleuchtungseinrichtung gemäß einem sechsten Ausführungsbeispiel, mit einem erfindungsgemäßen Optik-Vollkörper in einem vertikalen Längsschnitt; und
• 13 ein Ablaufdiagramm eines Verfahrens zur Herstellung eines erfindungsgemäßen Optik-Vollkörpers mit interner optisch wirksamer Schicht.

Further features and advantages of the present invention are explained in more detail below with reference to the figures. It is emphasized that individual features shown in the figures can also be essential to the invention on their own without the other features shown in the corresponding figure, even if this is not expressly mentioned in the description. In addition, it is emphasized that the features shown in the various figures can also be combined with one another in any way, even if such a combination is not expressly mentioned in the description. Show it:

• 1 a light module according to the invention for a motor vehicle lighting device according to a first exemplary embodiment, with an optical solid body according to the invention in a vertical longitudinal section;
• 2 the light module off 1 in a horizontal longitudinal section;
• 3 a light module according to the invention for a motor vehicle lighting device according to a second exemplary embodiment, with an optical solid body according to the invention in a vertical longitudinal section;
• 4 the light module off 3 in a horizontal longitudinal section;
• 5 a light module according to the invention for a motor vehicle lighting device according to a third exemplary embodiment, with a plurality of solid optical bodies according to the invention in a horizontal longitudinal section;
• 6 a light module according to the invention for a motor vehicle lighting device according to a fourth exemplary embodiment, with a plurality of solid optical bodies according to the invention in a horizontal longitudinal section;
• 7 a front view of an optics solid body according to one of 1 until 4 against a light exit direction;
• 8th a first alternative configuration of an optically effective layer inside a solid optics body 7 ;
• 9 a second alternative configuration of an optically effective layer inside a solid optics body 7 ;
• 10 a motor vehicle lighting device according to the invention according to a preferred embodiment;
• 11 a light module according to the invention for a motor vehicle lighting device according to a fifth exemplary embodiment, with an optical solid body according to the invention in a vertical longitudinal section;
• 12 a light module according to the invention for a motor vehicle lighting device according to a sixth exemplary embodiment, with an optical solid body according to the invention in a vertical longitudinal section; and
• 13 a flowchart of a method for producing an optical solid body according to the invention with an internal optically active layer.

In 1 an optical solid body according to the invention is denoted in its entirety by the reference numeral 10 . The optics solid body 10 is made of a solid transparent material. The material is, for example, glass or plastic, in particular PC or PMMI. The use of PMMA or another plastic material is also conceivable. The solid optics body 10 is part of a light module 12 for use in a motor vehicle lighting device 14 (cf. 10 ) educated.

In 10 a lighting device 14 according to the invention is shown in the form of a motor vehicle headlight. The lighting device 14 has a housing 34 which is preferably made of a plastic and includes a light exit opening 36 which is closed by a transparent cover plate 38 . The cover plate 38 is made of glass or plastic and can be designed with optically active elements (eg cylindrical lenses, prisms or the like) which scatter the light passing through, in particular in a horizontal direction. However, the cover pane 38 is preferably designed as a so-called clear pane without any optically active elements. The lighting device 14 is designed for installation in a corresponding installation opening of a motor vehicle. A light module 12 with a solid optics body 10 according to the invention is arranged inside the housing 34 . Several of the light modules 12 can also be arranged in the housing 34 . It is also conceivable that other light modules, in 10 symbolically represented by the reference number 13, are arranged inside the housing 34, which are designed, for example, to implement a lighting function (e.g. indicator light, cornering light, daytime running light, position light, etc.) or at least part of a headlight function (e.g. low beam basic light, low beam spotlight, high beam basic light, high beam spotlight, etc.).

The motor vehicle lighting device 14, in which the solid optics 10 according to the invention can be used, is not limited to a specific type of lighting device and can be designed, for example, as a headlight to generate a driving light (e.g. low beam and/or high beam), as a fog lamp to generate a fog light, as a cornering light to generate a cornering light or as a daytime running light to generate a daytime running light.

The solid optics body 10 includes a light coupling section 16 via which light from a light source 18 of the light module 12 can be coupled into the solid optics body 10 . In the example of 1 includes the optics solid body 10 two coupling sections 16a, 16b, each associated with a light source 18a, 18b. In this example, the light sources 18a, 18b are each designed as a light-emitting semiconductor element, for example as an LED (light-emitting diode) or an LD (laser diode). The light sources 18a, 18b are attached to a common printed circuit board 20 and electrically contacted via this. However, the use of light-emitting semiconductor elements without a circuit board would also be conceivable. Between the light sources 18 and the in-coupling sections 16 there can be arranged a bundling optics (so-called attachment optics) which bundles the light emitted by the respective light source 18 and guides it in the direction of the corresponding in-coupling section 16 . The bundling optics can consist, for example, of a catadiometric attachment optics, in which the central part of the emitted light beam is bundled with a collecting lens and at least part of the remaining light enters the attachment optics via a surface extending essentially parallel to the optical axis and is bundled at another interface by means of total internal reflection.

Furthermore, the optics solid body 10 includes a light decoupling section 22, via which at least a portion of the light coupled into the optics solid body 10 is coupled out of the optics solid body 10, so that the coupled light to the generation tion of at least part of a light distribution of the motor vehicle lighting device 14 is used in front of the motor vehicle. Finally, the solid optics 10 includes an optically effective layer 24 which is arranged in the beam path between the coupling-in section 16 and the coupling-out section 22 and is designed to change incident light.

At least part of the light coupled into the solid optics body 10 impinges on the optically effective layer 24 and is changed by it. In particular, an intermediate image is generated in an intermediate image plane by means of the optically active layer 24 . The intermediate image plane is preferably in the solid optics body 10. The intermediate image is produced by secondary or projection optics (cf. 3 and 4 ) is projected in front of the motor vehicle to generate the light distribution. The optically active layer 24 is preferably designed to absorb, transmit, reflect, refract, diffract, spectrally convert and/or filter the incident light in whole or in part.

In the example shown here, the internal optically effective layer 24 of the solid optics 10 is arranged and configured in such a way that it separates a first region 26 of the solid optics 10, to which a first light source 18a of the light module 12 is assigned, from a second region 28 of the solid optics 10, to which a second light source 18b of the light module 10 is assigned. Of course, it would also be conceivable to assign more than one light source 18 to each of the first and second regions 26, 28 of the solid optics body 10. The two areas 26, 28 of the solid optics body 10 preferably consist of the same solid, optically transparent material, in particular transparent material with the same refractive index.

In the example shown here, a common decoupling section 22 is assigned to the two regions 26 , 28 of the solid optics body 10 . However, it would also be conceivable to assign each of the areas 26, 28 its own decoupling section 22a, 22b.

The optically effective layer 24 can be configured completely flat or asymmetrically with a sloping section, as will be explained below. It lies on or runs parallel to an optical axis 30 of the solid optics body 10 or to two optical axes 30a, 30b of the first region 26 and the second region 28 of the solid optics body 10. The optically effective layer 24 is preferably designed as a screen that shades impinging light, in particular as a mirror screen that completely or partially reflects the impinging light in the direction of the decoupling section 22.

The first region 26 of the solid optics body 10 can be designed, for example, to generate a first light distribution of the illumination device 14 and the second region 28 to generate a second light distribution. The first light distribution is, for example, a shielded light distribution with a horizontal light-dark boundary (e.g. fog light) or an almost horizontal (asymmetrical) light-dark boundary (e.g. low beam). The first light distribution preferably alone satisfies the legal requirements for low beam or fog light. However, it would also be conceivable for the first light distribution to only meet the legal requirements for low beam or fog light in conjunction with another light distribution that is generated by another area of solid optics 10 or by another light module.

The second light distribution generated by the second area 28 illuminates, for example, an area of the light distribution above the light-dark boundary, and together with the shielded light distribution of the first area 26 of the solid optics body 10 generates a high-beam light distribution. This preferably meets the legal requirements for high beam. However, it would also be conceivable for the second light distribution to only meet the legal requirements for the high beam in conjunction with another light distribution that is generated by another area of the solid optics body 10 or by another light module.

Each of the regions 26, 28 of the solid optics 10 is assigned a coupling section 16a, 16b facing the corresponding light source 18a, 18b and a coupling-out section 22a, 22b. In this example, the two decoupling sections 22a, 22b of the first and second regions 26, 28 of the solid optics body 10 are—as stated—combined to form a common decoupling section 22 or formed by a single common decoupling section 22. The common decoupling section 22 of the solid optics body 10 can be designed as a lens, for example. In particular, the common decoupling section 22 has a light exit surface 32 that curves convexly outward.

A special feature of the present invention is that the optically effective layer 24--unlike in the prior art--is not formed or arranged on an outer boundary surface of the solid optics body 10, but rather in the solid body 10 itself. This enables the realization of particularly small solid optics 10 and light modules 12. In particular, it is now possible for the first time to realize two different light distributions, in particular low beam and high beam, by different areas 26, 28 of a common solid optics 10. In addition, the The solid optics body 10 according to the invention is inexpensive to manufacture, since an alignment and adjustment of various components (e.g. optically effective layer 24 relative to the coupling-in section 16 and/or to the decoupling section 22 or low-beam area 26 relative to the high-beam area 28) relative to one another can be omitted due to the one-piece optics solid body 10.

In the example of 1 and 2 the light decoupling section 22 forms at the same time a secondary or projection optics, in particular a projection lens, which projects the intermediate image from the intermediate image plane as light distribution of the light module 12 in front of the motor vehicle. This imaging effect is achieved in particular by the light exit surface 32 of the decoupling section 22, which is convexly curved outwards. The light exit surface 32 can be curved spherically or aspherically. An additional component in the form of the projection lens is thus integrated into the solid optics body 10 . A complex arrangement and alignment of the solid body 10 relative to the projection lens during the production of the light module 12 or the lighting device 14 can be omitted. In addition, such a solution takes up particularly little space.

In contrast, in the example 3 and 4 separate secondary or projection optics 40 are arranged downstream of the decoupling section 22 of the solid optics body 10 in the beam path. In the example shown, the secondary or projection optics 40 are designed as a projection lens with a light entry surface 42 and a light exit surface 44 . In the example shown, a vertical section (cf. 3 ) Biconvex projection lens 40 is provided, which has a convex light entry surface 42 and a convex light exit surface 44 . In particular, the projection lens 40 is designed as a cylindrical lens (cf. 4 ). Other configurations of the secondary or projection optics 40 are also conceivable. A separate secondary or projection optics 40 has the advantage that the refraction of the exiting light for imaging the intermediate image from the intermediate image plane can be divided as light distribution in front of the motor vehicle onto a plurality of light passage surfaces 32, 42, 44. As a result, a preferably high-resolution light distribution can be implemented with greater accuracy, and a greater degree of design freedom results.

As a result of the novel solid optics body 10 with an integrated optically active layer 40, the secondary or projection optics 40 have a particularly short focal length, which can be, for example, in the range of just 50 mm (+/−20 mm). This is a very small value for a motor vehicle headlight 14 since the focal lengths of the corresponding secondary or projection optics of previously known headlights were in the range of at least 100 mm.

The light sources 18 each emit light in a main emission direction. The main emission direction can be aligned parallel, obliquely or perpendicularly to an optical axis 30 of the solid optics body 10 . In a preferred orientation slightly oblique or parallel to the optical axis 30 (cf. 1 until 6 and 11 ), the light coupled into the solid optics 10 can be directed directly in the direction of the optically effective layer 24 of the solid optics 10 and does not have to be deflected on the way there by the solid optics 10 . In the case of an alignment that is also conceivable, it is strongly inclined or perpendicular to the optical axis 30 (cf. 12 ), it may be necessary for the solid optics 10, viewed in the main emission direction of the light source 18, to have a primary optics section 50 opposite the coupling section 16, which is designed to focus at least part of the light coupled into the solid optics 10 and/or to deflect it in the direction of the optically active layer 24 of the solid optics 10. The primary optics section 50 can have a reflection surface 52a which is formed or arranged in a conventional manner on an outer boundary surface of the optics solid body 10 . Alternatively, the reflection surface 52b can also be formed by an optically effective layer, which is formed or arranged inside the solid optics body 10 in the sense of the present invention. It is therefore conceivable that the solid optics body 10 also has a plurality of optically effective layers 24, 52b.

An advantage of the present invention lies in the production of the optically effective layer 24 within the solid optics body 10 for the realization of a diaphragm, in particular also a mirror diaphragm, a spectral converter, a filter or the like. This enables a very compact construction of multi-function modules 12. Furthermore, an internal delimitation of the solid optics body 10 between optical areas 46 and non-optical areas 48 can be realized by the internal optically effective layer 24 (cf. 11 and 12 ). Overall, the outlay for installation can be reduced, since only a solid optics body 10 with an integrated diaphragm arrangement is required instead of an additional diaphragm arrangement, and the partial separation of light paths (cf. 1-4 ) the function integration can be increased.

The design and production of the optically effective layer 24 inside the solid optics body 10 is explained in more detail below. A variety of different configurations and/or functions of the optically active layer 24 are conceivable. For example, the optically active layer 24 can take on the function of a diaphragm, in particular a mirror diaphragm, with an appropriate configuration (cf. 1 until 6 ). The invention makes it possible, among other things, to implement the function of a mirror diaphragm within a solid optics body 10 without having to rely on reflection at an outer boundary surface of the solid body 10 .

In the examples of 11 and 12 the optical region 46 of the solid optics body 10 is used to form the light distribution. The non-optical area 48 behind the diaphragm 24, which is shaded by the optically active layer 24, ie to which no light reaches, can take on non-optical tasks. For example, the non-optical area 48 can be used for arranging fastening elements 54, which can be used to fasten the solid optics body 10 in the light module 12 or the light module 12 in the housing 34 of the lighting device 14 or the like. This would not be possible in the prior art since the diaphragm would be arranged on the outside on an outer boundary surface of the solid optics body 10 .

In order to arrange the diaphragm arrangement 24 inside the solid optics body 10, a film 24a or a coating 24b with absorbent and/or reflective properties can be introduced into the material of the solid optics body 10 as an intermediate step during the production of the solid optics body 10, e.g. by means of a multi-layer injection molding process or a multi-component multi-layer process. In particular, the foil 24a or the coating 24b can be applied to a partial optical solid body 46 (cf. 12 ) or 26 (cf. 1 and 3 ) applied and then in a subsequent production step with a further layer 48 or 28 of the material of the optics solid body 10 over- or encapsulated. A boundary between the partial optics solid body 46 and the other layer 48 of the material is in the example 12 formed by the film or coating 24 and by two internal boundary surfaces 56 shown in dashed lines. In the area of the internal boundary surfaces 56, the materials of the partial optics solid body 46 and the further layer 48 fuse to form a common optics block. In particular, preferably no total reflection occurs at the boundary surfaces 56, since the materials of the partial optics solid body 46 and the further layer 48 have the same refractive index.

The film 24a has a light-reflecting and/or light-absorbing surface at least on one side that faces the light originating from the coupling-in section 16 or from the primary optics section 50 . An absorptive surface can absorb at least a portion of the incident light and shade the absorbed portion of the coupled light to form a desired light distribution. The absorbing surface is, for example, matt, in particular matt black. By means of such a shaded screen, it would be conceivable, for example, to generate a shaded area of the light distribution. An edge of the panel, in particular a front edge of a horizontal panel, can be imaged by the secondary or projection optics as the light-dark boundary of the light distribution. The light-dark boundary is located at the transition between an illuminated area of the light distribution and the shaded area. The light-dark boundary can have a horizontal or almost horizontal (asymmetrical) progression, for example to generate a fog light or low beam or a part thereof. Likewise, the light-dark boundary can have a vertical or almost vertical profile, for example to generate a partial high beam or a part thereof, in which areas of the light distribution in which other road users were detected are shaded in order to avoid dazzling them.

A reflective surface of the foil 24a can reflect incident light (so-called specular reflection), so that it is not lost but can contribute to the generation of the light distribution. As a result, a light distribution can be formed with a light-dark boundary and a shaded area above the light-dark boundary and an illuminated area below the light-dark boundary, which includes the light that has passed mirror panel 24 on the one hand and at least part of the light reflected by mirror panel 24 on the other. In this way, a particularly efficient light distribution with a light-dark boundary can be generated.

Instead of inserting a film 24a in an intermediate step in the production of the solid optics body 10, it would also be conceivable to apply a coating 24b, e.g. in the form of a selective metallization, to the previously produced solid optics part 46 or 26 in the intermediate step between two injection molding cycles, and then to overmold this coating 24b with a further layer 28 of the material of the solid optics body 10. The coating 24b can, for example, be a color (eg matt black) that can be sprayed onto the previously produced solid partial optics body 46 or 26 . However, the coating 24b can also be applied, for example, by means of sputtering or vapor deposition to the previously produced solid partial optics body 46 or 26 . The metallization layer 24b comprises a metal, preferably with good reflection properties, in particular Aluminum (Al), Silver (Ag), Chromium (Cr) or the like.

Furthermore, the film 24a or the coating 24b could also be designed to be partially transparent, i.e. part of the light striking the optically active layer 24 passes through the film 24a or the coating 24b and another part of the light is absorbed and/or reflected by the film 24a or the coating 24b. This has the advantage that the part of the light transmitted through the optically effective layer 24 can reach the shaded area of a shielded light distribution, in particular above the light-dark boundary, and can be used there within the framework of the light distribution for realizing special lighting tasks. In this way, for example, overhead lighting of a low beam can be implemented above the light-dark boundary.

The optically effective layer 24 introduced into the solid optics body 10, e.g. the film 24a or coating 24b, is preferably designed and shaped in such a way that it generates an intermediate image in an intermediate image plane, which can be imaged by the secondary or projection optics 40 or 32 to generate the resulting light distribution in front of the motor vehicle. In particular, the optically effective layer 24 is designed and shaped so that it is in the intermediate image plane 60 (cf. 2 and 4 ) generates an intermediate image that can be imaged by the secondary or projection optics 40 or 32 to generate a shielded light distribution (eg low beam, fog light, cornering light) or a partial high beam in front of the motor vehicle. The intermediate image plane 60 is preferably located in the interior of the solid optics body 10. The intermediate image plane 60 is very particularly preferably located on an edge 58, in particular on a front edge of an optical axis 30; 30a, 30b of the solid optics body 10 or diaphragm arrangement 24 running parallel thereto. This edge 58 can be imaged by the secondary or projection optics 40 or 32 as the light-dark boundary of the light distribution in front of the motor vehicle.

The leading edge 58 and the intermediate image plane 60 can be seen in a plan view (cf. 2 and 4 ) have a straight or flat course (not shown). However, the edge 58 and the intermediate image plane 60 preferably have a curved profile. The curved course preferably follows the focal points of the exit surface 32 of the decoupling section 22 or of the projection lens 40.

This curved shape of the front edge 58 of the diaphragm 24 can be advantageous for correcting aberrations in the light distribution.

In addition, it would be conceivable to design the optically effective layer 24 in such a way that it completely or partially converts light of a first spectrum coupled into the solid optics body 10 into light of a different spectrum, i.e. changes the color of the light. This can be realized, for example, in that the optically effective layer 24 only reflects and/or absorbs the light components of a specific frequency spectrum. In this context, it would be conceivable, for example, for the optically effective layer 24 to have a specific coloration, e.g. red, green or blue, on its surface facing the coupling-in section 16 or the primary optics section 50, in order to specifically change the coloration of the light of the resulting light distribution. The coloring on the surface of the optically effective layer 24 can be applied, for example, by means of spraying, sputtering or vapor deposition of color onto a previously produced partial solid optics body 46 or 26 and then overmolded or encapsulated with material 48 or 28 of the solid optics body 10 . However, it would also be conceivable for a film 24a to have such a colored layer. Changing the color of the light may be necessary if the light source 18 used only emits light of a specific color that cannot be easily changed at the light source 18 itself. Here, the optically effective layer 24 with spectral-transforming properties offers an easily realizable option for color correction of the light of the resulting light distribution. Individual wishes of motor vehicle manufacturers regarding the color of the light for the headlights of their vehicles (some manufacturers prefer greenish white light for the headlight functions, others prefer bluish or yellowish white light) can be easily and inexpensively taken into account in this way.

Since only part of the light coupled into the solid optics body 10 strikes the optically active layer 24 and can therefore be changed spectrally or in color at all, the color of the light can only be changed slightly by the optically active layer 24 with spectral-changing properties. As a result, for example, daylight white light (over 5,300 K) can be converted into warm white light (under 3,300 K) with a relatively high proportion of yellow or into cold white light (approx. 7,000-9,000 K) with a higher proportion of blue and/or green.

Alternatively or additionally, it would also be conceivable to configure the optically effective layer 24 in such a way that it has light-filtering properties. In this case, the layer 24 only reflects incident light of a specific frequency spectrum. The remaining frequency spectrum of the light is transmitted or absorbed. The optically effective layer 24 in the form of an optical filter can have a simple color coating or more complex alternatives, for example an interference filter. The interference filter can comprise one or more diffraction structures lying one on top of the other. However, the interference filter can also include several partially transparent metallic mirror layers (e.g.: silver, aluminum). The optically effective layer 24 in the form of an optical filter can be applied, for example, by means of sputtering, spraying or vapor deposition onto a previously produced partial solid optics body 46 or 26 and then overmolded or encapsulated with the material 48 or 28 of the solid optics body 10 . However, it would also be conceivable for a film 24a to have such an optically filtering layer. If necessary, the film 24a comprises a transparent carrier layer, to which various layers are then applied, which realize the optically filtering effect of the light that passes through and/or is reflected.

The optically effective layer 24 inside the solid optics body 10 can also be designed as a totally reflecting layer 24c (cf. 11 ). This can be formed inside the solid optics body 10, for example, by creating at least one internal volume (or medium) 48 with a different refractive index compared to the remaining volume (or medium) 46 of the solid optics body 10, so that an internal optically effective boundary surface results between the internal volume 48 with the different refractive index and the remaining volume 46 of the solid optics body 10, which totally or partially reflects the incident light. In a preferred embodiment, the internal volume 48 in which the light propagates has a greater refractive index than the remaining volume 46. The volumes 46, 48 with different refractive indices can be formed, for example, during the manufacture of the optic solid body 10 as part of a multi-layer injection molding process by using transparent material with different refractive indices in the various successive manufacturing steps to produce the corresponding volumes 46, 48.

The material of the at least one internal volume 48 with the different refractive index preferably has the same coloration as the remaining volume 46 of the solid optic body 10. However, it would also be conceivable for the material of the at least one internal volume 48 to have a different coloration.

The optically effective layer 24 can be flat and lie on an optical axis 30 of the solid optics body 10 or run parallel to the optical axis 30 . When the lighting device 14 is built into a motor vehicle as intended and the light module 12 with solid optics body 10 is arranged therein as intended, the optically effective layer 24 can extend in a horizontal plane. In this way, dimmed light distributions with a light-dark boundary with a strictly horizontal progression, for example a fog light, a cornering light or a cornering light or a basic low beam light, can be generated.

7 shows a view of the optics solid body 10 according to one of 1 until 4 against a light exit direction 68. According to this embodiment, it is proposed that the optically effective layer 24 has a first flat section 62, which extends from one side 64 of the solid optics body 10 in the direction of a vertical center plane 66 of the solid optics body 10, in particular in the direction of the optical axis 30; 30a, 30b of the solid optics body 10 extends. The horizontal section 62 is--viewed in the light exit direction 68--on the traffic side (right for right-hand traffic; left for left-hand traffic) of the vertical center plane 66. After the projection by the secondary or projection optics 40 or 32, the flat section 62 is used, for example, to generate a horizontal section of an asymmetrical light-dark boundary of a low beam according to ECE or a low beam spotlight. The horizontal section of the light-dark boundary is—seen in the light exit direction 68—arranged in front of the motor vehicle on the oncoming traffic side, in particular on the oncoming traffic lane.

The first section 62 is followed by a sloping section 70--preferably at a 15.degree. However, it would also be conceivable for the sloping section 70 to be arched or even stepped (not shown). The sloping section 70 extends in the direction of a second side 72 of the solid optics body 10 opposite the first side 64 . The section 70 is—viewed in the light exit direction 68 —arranged on the opposite traffic side of the vertical central plane 66 . After the projection by the secondary or projection optics 40 or 32, the falling section 70 is used, for example, to produce a rising section of an asymmetrical light-dark boundary of a low beam according to the ECE standard or a low beam spotlight. The rising section of the light-dark boundary is—seen in light exit direction 68—arranged in front of the motor vehicle on the traffic side of the car, in particular at the edge of the traffic side of the car and/or on the car's own lane.

According to the example described, the optically effective layer 24, in particular when it is designed as a diaphragm or mirror diaphragm, thus has a planar extension with a kink along an optical axis 30; 30a, 30b or along a line parallel to an optical axis 30; 30a, 30b or along the center plane 66. The front edge 58 of the layer 24 is--as already described above--preferably curved counter to the light exit direction 68. The front edge 58 of the optically active layer 24 thus extends further on the opposite sides 64, 72 in the light exit direction 68 than in the area of the vertical center plane 66 (cf. 2 and 4 ) which runs through at least one of the optical axes 30a, 30b or parallel thereto.

In the 8th and 9 alternative configurations of the optically active layer 24 are shown. All share the flat portion 62, but the configuration of the sloping portion 70 differs from the example in FIG 7 . In the example off 8th the sloping section 70 comprises a - preferably at a 15° angle - sloping first section 74, then a substantially horizontal second section 76, then in turn a rising third section 78 and then finally a flat fourth section 80. The second section 76 runs below the flat section 62 and preferably parallel thereto. The third section 78 may rise at a 15° angle or any other angle. The fourth section 80 preferably runs at the same height as the flat section 62 and is congruent or parallel thereto.

On the example 9 includes the sloping section 70 a - preferably vertically downwards - sloping first section 82 and then a substantially horizontal second section 84. The second section 84 runs below the flat section 62 and preferably parallel to it. The first section 82 forms a stepped transition between the flat section 62 and the second section 84.

The 7 until 9 show the shape of the optically effective layer 24 in the form of a screen or mirror screen for right-hand traffic. It goes without saying that in the case of left-hand traffic, the curves of the optically active layer 24 shown would run approximately in a mirrored manner at the vertical center plane 66 .

In the 5 and 6 two exemplary embodiments of a light module 12 with a plurality of solid optic bodies 10 are shown. In the examples, three solid optics 10 are arranged next to one another. Of course, more or fewer than the three solid optics bodies 10 can also be arranged next to one another. It would also be conceivable to arrange the solid optics 10 one above the other or offset at an angle to one another. The arrangement of the solid optics 10 depends on the space available in the motor vehicle (shape and size of the installation opening in the body) and/or on design specifications. The solid optics 10 can be arranged next to one another on a horizontal plane or on a plane running at an angle to the horizontal plane, so that—viewed counter to the light exit direction 68—the solid optics 10 or their light exit surfaces 32 have a rising or falling profile.

The individual optics solid body 10 of a light module 12 are - as in the 5 and 6 shown - preferably be designed as a single, jointly manufactured one-piece optical component. Alternatively, individual or all solid optics 10 of such a light module 12 can also be designed as separate optical components (not shown).

In the example of 5 the secondary or projection optics are integrated into the decoupling section 22 of the solid optics body 10 . In particular, the function of the optics is taken over by the light exit surface 32 of the decoupling section 22 . In contrast, in the example of 6 a separate secondary or projection optics 40 is provided. In a preferred embodiment, the common light exit surface is smooth and continuous, in particular with constant curvature.

In the examples of 5 and 6 the optical axes 30 of the individual solid optics bodies 10 run parallel to one another. Of course, it would also be conceivable for the optical axes 30 to run at an angle to one another, so that they intersect at at least one point of intersection, preferably at a common point of intersection for the optical axes 30 of all solid optics bodies 10 of a light module 12.

In the examples of 5 and 6 it is possible that light coupled into a solid optics body 10 of a light module 12 can reach an adjacent solid optics body 10 of the light module 12 . This can have the advantage that the resulting light distribution is homogenized. On the other hand, such a crosstalk of the light beams from a solid optics body 10 into an adjacent solid optics body 10 can also be disadvantageous, e.g. because it leads to scattered light that is difficult to control and/or because the realization of a preferably high-resolution light distribution is made more difficult. In this case it can be beneficial be to introduce optically active layers 24 in the form of partition walls 84 into the common optical component, which forms the solid optics 10, between individual or all solid optics 10, which prevent crosstalk of the light beams (cf. 5 ). In this regard, it is suggested that the partitions 84 have reflective properties on both surfaces. If low crosstalk of the light beams is desired, the dividing walls 84 can be designed to be partially transparent. It is also advantageous if the partition walls 84 have a planar surface extension. The partition walls 84 can be introduced into the common optical component in the manner described above as foils 24a or coatings 24b during the production of the same.

13 shows a flowchart of a method for producing a solid optics body 10 according to the invention with an internal optically effective layer 24. The method begins in a step 86. Then, in a first step 88 of the production method, which is, for example, a multi-layer injection molding process, a partial solid optics body 26 or 46 is produced from the material of the solid optics body 10, for example by injection. In a subsequent intermediate step 90, the optically effective layer 24 can then be applied at least to a partial area of the partial optics solid body 26 or 46. The application of the optically active layer 24 can - as described in detail above - the arrangement of a foil 24a or a corresponding shaped body or the application (e.g. sputtering, spraying, brushing, vapor deposition or the like) of a coating 24b (e.g. a metallization layer, a color layer or the like). Subsequently, in a further method step 92, the applied optically active layer 24 is sprayed or encapsulated with the material of the solid optics body 10. In the example, therefore, the intermediate step 90 is carried out between two injection molding cycles 88, 92. The method ends in a step 94.

If more than one optically active layer 24 is to be introduced into the solid optics body 10, steps 90 and 92 must be repeated until the solid optics body 10 with the intended number of optically active layers 24 is completed.

If the optically effective layer 24 is to be formed as a totally reflecting layer 24c inside the solid optics body 10, in the first method step 88 the partial solid optics body 26 or 46 is produced from the material of the solid optics body 10 with a first refractive index, which forms a first volume of the solid optics body 10. The intermediate step 90 is skipped since the application of a separate element as the optically active layer 24 is not necessary. Then, in method step 92, the partial solid optics body 26 or 46 is overmolded or encapsulated with material of the solid optics body 10 with a refractive index that differs from the first refractive index, so that an internal volume 28 or 48 with a different refractive index is formed. In this way, between the internal volume 28; 48 with the different refractive index and the first volume 26; 46 with the first refractive index has an internal interface that totally or partially reflects the incident light. This internal interface 24c forms the optically effective layer 24 inside the solid optics body 10.

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• EP 1357333 A2 [0005, 0006]

Claims (17)

Solid optics (10) made of a solid transparent material for use in a light module (12) of a motor vehicle lighting device (14), the solid optics (10) comprising a light coupling section (16) via which light from a light source (18) of the motor vehicle lighting device (14) can be coupled into the solid optics body (10), and a light decoupling section (22) via which at least part of the light coupled into the solid optics body (10) can be emitted from the solid optics body ( 10) decoupled, so that the decoupled light is used to generate at least part of a light distribution of the motor vehicle lighting device (14) in front of the motor vehicle, and the solid optics (10) also has an optically active layer (24) arranged in the beam path between the coupling section (16) and the decoupling section (22), which is designed to change incident light,characterizedthat the optically effective layer (24) is formed inside the optics solid body (10). Optics full body (10) according to claim 1 , characterized in that the optically effective layer (24) is designed to absorb, transmit, reflect, break, diffract, spectrally convert and/or filter the incident light in whole or in part. Optics full body (10) according to claim 1 or 2 , characterized in that the optically effective layer (24) comprises a foil (24a) or a coating (24b) which has a light-reflecting and/or light-absorbing surface at least on a side facing the coupling section (16) of the solid optics body (10). Solid optics (10) according to one of the preceding claims, characterized in that the optically effective layer (24c) is formed by two areas (26, 28; 46, 48) of the solid optics (10) on opposite sides of the optically active layer (24), the two areas (26, 28; 46, 48) of the solid optics (10) consisting of materials with different refractive indices. Solid optic body (10) according to one of the preceding claims, characterized in that the optically effective layer (24) is designed to convert the incident light of a first spectrum wholly or partially into light of a different spectrum. Solid optic body (10) according to one of the preceding claims, characterized in that the optically active layer (24) is designed to reflect only part of the spectrum of the incident light. Optics full body (10) according to claim 6 , characterized in that the optically effective layer (24) is designed to absorb and/or transmit the non-reflected part of the spectrum of the incident light. Solid optics (10) according to one of the preceding claims, characterized in that the optically active layer (24) is designed to achieve a partially transparent effect, with the optically active layer (24) reflecting part of the incident light and the reflected light after being coupled out of the solid optics (10) to generate at least part of a shielded light distribution with a horizontal light-dark boundary, and light transmitted through the optically active layer (24) after being coupled out of the solid optics (10) is used to generate overhead lighting above the light-dark limit of the shielded light distribution. Solid optics (10) according to one of the preceding claims, characterized in that the solid optics (10) has a primary optics section (50) which is designed to focus at least part of the light coupled into the solid optics (10) and/or to deflect it in the direction of the optically active layer (24) of the solid optics (10). Solid optics (10) according to one of the preceding claims, characterized in that the decoupling section (22) of the solid optics (10) has a projection lens which is designed to image an intermediate image formed in an intermediate image plane (60) in the solid optics (10) as the light distribution of the motor vehicle lighting device (14) or as part of the light distribution in front of the motor vehicle. Optics full body (10) according to claim 10 , characterized in that the optically active layer (24) has an edge (58) arranged inside the solid optics body (10) and in that the intermediate image plane (60) is arranged in the region of the edge (58) of the optically active layer (24). Solid optics (10) according to one of the preceding claims, characterized in that the optically effective layer (24) has a first substantially horizontal section (62) which extends from a first side (64) of the solid optics (10) in the direction of a vertical central plane (66) of the solid optics (10) and to which a second sloping section extends (70), which extends in the direction of a second side (72) of the solid optics body (10) opposite the first side (64). Solid optics (10) according to one of the preceding claims, characterized in that the optically effective layer (24) runs parallel to or on an optical axis (30; 30a, 30b) of the solid optics (10). Light module (12) of a motor vehicle lighting device (14), with a light source (18) and a solid optics body (10), wherein the light source (18) is designed and arranged and aligned with respect to the solid optics body (10) so that it emits light in a main emission direction in the direction of a light coupling section (16) of the solid optics body (10), and wherein the solid optics body (10) is formed via the coupling section (16) into the solid optics body (1 0) changing coupled-in light by means of an optically effective layer (24) onto which at least part of the coupled-in light strikes, so that light coupled out via a coupling-out section (22) of the solid optics (10) generates at least part of a light distribution of the motor vehicle lighting device (14) in front of the motor vehicle,characterizedthat the optics solid body (10) is formed according to any one of the preceding claims. Light module (12) after Claim 14 , characterized in that the light module (12) has a plurality of light sources (18) and/or a plurality of solid optics (10). Light module (12) after Claim 14 or 15 , characterized in that the light module (12) has a projection lens (40), which is arranged downstream of the decoupling section (22) of the solid optics (10) in the beam path and is designed to image an intermediate image formed in an intermediate image plane (60), which is preferably arranged in the solid optics body (10), as the light distribution of the motor vehicle lighting device (14) or as part of the light distribution in front of the motor vehicle. Motor vehicle lighting device (14) with a housing (34) which has a light exit opening (36) closed by a cover plate (38) and inside the housing (34) a light module (12) which, in order to generate a light distribution of the motor vehicle lighting device (14) or a part thereof, projects light in front of the motor vehicle, characterized in that the light module (12) according to one of the Claims 14 until 16 is trained.

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