CZ2022146A3 - A lamp for a car and a method of making a lamp for a car - Google Patents

Abstract

The subject is a lamp for an automobile, which includes a support frame (1), a silicon optical element (2), a mounting frame (3) and a set of light sources (4). The silicone optical element (2) includes a body (5) and a set of protrusions (6) for light entry, and the mounting frame (3) includes for each protrusion (6) for light entry a passage (7) for stabilizing the protrusion, each protrusion (6) for the input of light, it passes through the given passage (7) towards the corresponding light source (4). Furthermore, the lamp includes at least one leveling projection (8), while the attachment frame (3) is attached to the supporting frame (1) in a position defined by at least one leveling projection (8). The silicone optical element (2) is clamped between the attachment frame (3) and the support frame (1). Another subject is the method of production of this lamp.

Description

A flashlight for a car and a method of making a flashlight for a car

Field of technology

The present invention is directed to lamps for automobiles with silicon-based optical elements and to a method of manufacturing such a lamp.

Current state of the art

In addition to the light source and the cover or frame, which holds the other parts of the lamp together, the lamps for cars also include a primary and a secondary optical element as standard. The secondary optical element is, for example, the cover glass of the lamp, i.e. the outermost translucent part, while the primary optical element is closer to the light source and serves to adjust the light emitted by the light source, for example to homogenize the light from individual LED sources so that the light emerging from the lamp does not have the form of distinguishable points of light or circles.

In recent years, silicon optical elements have been increasingly used as the primary optical element. Silicone has the advantage that, unlike glass, it is significantly lighter and usually more durable and cheaper. Compared to other polymers, its main advantage is that it provides desirable optical properties while being significantly softer and more flexible, so it is possible to cast it into more complicated shapes, e.g. with bevels, which would make an element made of glass or a harder polymer impossible can be removed from the mold, and it is possible to create thinner structures from it without the risk of cracking or breaking. The silicone optical element thus often includes thin protrusions used for the input of light from individual sources, most often LED sources, and for the collimation of this light.

Due to the higher flexibility of silicone, silicone optical elements are normally attached to light sources by means of holding frames, which are, for example, screwed to the light source and press the optical element towards the source. Another consequence of the flexibility of silicone is that due to gravity or shocks while driving, these collimation protrusions would bend, so that the light from the sources would not enter the protrusions in exactly the desired position or direction, which would result in a decrease in the intensity or deterioration of the homogeneity of the light emitted from the lamp. Lamps with silicone optical elements including collimating lugs are therefore provided with metal frames with holes that hold the lugs in the desired position relative to the light sources.

Such a lamp is described, for example, in document US10793057 B2. The light source in this document is a printed circuit board with an LED array, to which a silicon optical element is attached by a two-part holding frame that surrounds both the printed circuit board and the optical element. To secure the collimation protrusions in the desired position, a perforated frame is inserted between the optical element and the light source, through the holes of which the individual collimation protrusions pass.

The disadvantage of existing lamps with silicone optical elements is their complicated production. The silicone optical element must be placed on a frame with holes, which stabilizes the collimating protrusions, and then the silicone element is pressed against the light sources with the holding frame. At the same time, the silicone optical element must be precisely aligned with respect to the light sources and the frame with holes, misalignment of the optical element by less than a tenth of a millimeter, for example, can cause a drop in the intensity of the light coming out of the lamp, for example, by up to a quarter. The light source with the attached optical element then needs to be precisely attached to the supporting frame, which is another production operation with high demands on precision.

It would therefore be advisable to come up with a solution for a lamp for cars with a silicon optical element, which would reduce the complexity of production, whether in terms of time, financial costs or the demands placed on the workers assembling such lamps.

- 1 CZ 2022 - 146 A3

The essence of the invention

The shortcomings of the solutions known from the prior art are to some extent eliminated by a lamp for a car, which includes a support frame, an optical element based on silicon, a mounting frame and a set of light sources containing at least two light sources. The silicon optical element includes a body provided with a surface for light exit, and further, the silicon optical element for each light source of the plurality of light sources includes a protrusion for light entry. The free end of the protrusion faces the given light source and these protrusions serve to guide light from the sources into the body of the silicon optical element and to collimate this incoming light. The mounting frame includes for each light entry projection a passage for stabilizing the projection, each light entry projection passing through said passage from the body towards the corresponding light source.

The attachment frame is attached to the support frame in a position defined by at least one leveling protrusion fitting into a recess on one frame of the attachment frame and the support frame. Preferably, this position is clearly determined and preferably is determined precisely enough so that after attaching a set of light sources, e.g., to the supporting frame, the individual light sources are sufficiently precisely aligned with the protrusions for light entry supported by passages for stabilizing the protrusions. A set of light sources can be attached, for example, to a mounting frame. The compensating projection further fits into the recess on the second frame from the support frame and the attachment frame or is attached to the second frame from this pair, while the silicone optical element is pressed against the support frame by the attachment frame, i.e. it is clamped between the two frames. The mounting frame can thus also be designated as a pressure frame or a frame for attaching a silicon optical element, etc. The compensating element is preferably attached to the supporting frame, in particular it is preferably a fixed part of it, e.g. they are cast in one piece, while passing through the mounting frame and especially preferably and a supporting element of a set of light sources, e.g. a heatsink and/or a circuit board.

A plurality of light sources may also contain significantly more than two light sources, for example several tens to several hundreds. There is preferably an appropriate amount of protrusions for the entry of light and passages for stabilization of the protrusions. However, it is also possible, for example, to use one protrusion in one passage to connect light from several sources at the same time.

The fundamental advantage of a silicone optical element, which can be made from pure silicone but also from silicone supplemented with other materials, suitable additives, etc., is low weight and price (especially compared to glass), resistance to burning (especially compared to commonly used plastics , e.g. PMMA) and also the possibility of casting more complicated shapes. A fundamental advantage of the lamp according to the invention, compared to known lamps with silicon optics, is that the fixing frame, which holds the silicon optical element in the right place, also serves as a stabilizing part for the collimation protrusions for the light input of the silicon optical element. This is made possible, among other things, by the fact that the mounting frame is mounted to the support frame, not to the set of light sources. It is therefore not necessary to use a separate part to stabilize the protrusions for the light input, and the need to precisely center another component of the lamp is eliminated, which also limits the resulting inaccuracies that would add up among a larger number of components. The mounting frame is preferably made of sheet metal. However, it can also be, for example, made of plastic or metal in a form other than sheet metal.

The exact position of the silicon optical element relative to the support frame is then ensured by means of the fixing frame with an alignment protrusion, preferably at least two alignment protrusions. These protrusions are shaped in such a way as to remove the degrees of freedom between these components when the said components are installed, i.e. in particular to prevent shifting and rotation between the frames, and as a result, rotation or shifting of the silicon optical element. Preferably, the projection is on the supporting frame and the mounting frame has a complementary shaped opening or cut-out. Preferably, the position of the silicon optical element is further defined by means of suitable complementary shape elements on the support frame and the silicon optical element, for example using a flange in the opening for the passage of outgoing light, into which the silicon optical element is inserted, while the edge of the element rests on the flange. Preferably, the flange and/or other part is further away

- 2 CZ 2022 - 146 A3 equipped with protrusions or recesses to ensure exact position thanks to complementary recesses or protrusions on the silicon optical element.

The attachment frame can be attached to the supporting frame, for example, by means of flexible shaped handles, but it is also possible to screw or glue, etc. The exact position is then ensured, for example, by a combination of leveling protrusions with flexible grips, where the protrusions precisely define the positions and the grips prevent the frame from coming off the leveling protrusions . Finally, a tight and precise connection of the two frames can be ensured by attaching a plurality of light sources to the support frame with the attachment frame pressed between them. The passages for stabilizing the protrusions are preferably through holes with a cross-section corresponding to the cross-section of the protrusions for the entrance of light. However, it is also possible, for example, to implement passages as cut-outs on the sides of the mounting frame. On the resulting lamp, there are advantageously precisely aligned light sources from a set of light sources, protrusions for the entry of light and passages for stabilizing the protrusions. The flashlight can also include other light sources, the silicon optical element and its corresponding set of light sources can, for example, represent only one of the many modules of the headlight, while other modules can be implemented similarly, but they don't have to.

The plurality of light sources may include a heat sink and a printed circuit board on which the light sources are located, the printed circuit board being glued to the heat sink and attached to the support frame. This attachment of the printed circuit board to the supporting frame can be realized directly or indirectly, in particular by means of a heatsink. Thus, for example, the heatsink can be bolted to the support frame, the printed circuit board glued to the heatsink, and the light sources, especially the LED sources, attached to the printed circuit board.

After gluing the printed circuit board to the heatsink, the adhesive may bulge, the printed circuit board may curl, or other irregularities may appear on the printed circuit board. These irregularities may not be visible to the naked eye and yet can shift or tilt the individual light sources to such an extent that the lamp's luminance is reduced because more of the light from the source is radiated away from the entry surface of the light entry lug or is radiated onto it at an inappropriate angle. Therefore, in the prior art, it may be necessary to rapidly cure the adhesive in an oven to maintain the flatness of the adhesive layer and the printed circuit board.

To avoid this PCB inaccuracy problem and to eliminate the need for environmentally and economically costly oven curing, the silicon optical element preferably includes at least one push tab for aligning the printed circuit board, the push tab being clamped between the printed circuit board and the support frame, wherein the printed circuit board is pushed to the heatsink by the pusher. This alignment of the printed circuit board can be advantageously ensured by placing at least one push protrusion around the protrusions for the light input and thus also around the light sources. This can be accomplished by using a single protrusion surrounding a larger part of the circumference of the silicon optical element or by using multiple protrusions. When viewed in the direction of the lamp axis, there are preferably at least two, more preferably at least three, directions inclined to each other by at least 45°, more preferably at least 60° for each light input projection, in which a half-line starting in a given light input projection intersects a push projection.

The lamp is preferably assembled before the glue hardens. Any unevenness in the adhesive layer or deviations of the printed circuit board from the planar shape are then leveled by pressure from the pressure projections. Thanks to the flexibility of silicone, any dirt, e.g. dust, on the contact surface between the printed circuit board and the push-out lugs will not affect the alignment of the printed circuit board, because the unevenness caused by the dirt is smoothed out by the silicone, or the impurity "sinks" into the silicone. The printed circuit board does not need to rest directly on the support frame anywhere, or it only touches it on the leveling protrusion.

Preferably, therefore, the silicon optical element includes a plurality of push protrusions for aligning the printed circuit board, the push protrusions being distributed around the light entry protrusions. Alternatively, advantageously, one push lug can surround the lugs for the entry of light from multiple directions.

- 3 CZ 2022 - 146 A3

There are preferably at least three push protrusions, preferably not lying on one straight line. Thus, such protrusions define a triangle, while preferably inside such a triangle, or generally an n-gon, lies at least part of the light sources.

Preferably, the leveling projection is attached to the support frame and passes through the attachment frame into a recess in the printed circuit board. The leveling lug therefore levels not only both frames, but also the printed circuit board and thus the light sources. The leveling protrusion also extends particularly advantageously into the radiator. A set of light sources can be placed on a structural element other than a printed circuit board to facilitate assembly and ensure the distribution of individual sources. In such a case, the compensating protrusion preferably extends up to such a structural element.

Advantageously, the lamp includes at least two leveling projections. For example, it can be two cylindrical or conical protrusions. The mounting frame, and optionally the set of light sources, optionally also the silicon optical element, can then include through holes for mounting on the leveling protrusions. For example, the mounting frame may include a round lug and an oval one to allow fitment of the two alignment lugs even in the case of certain inaccuracies that would make it impossible to fit a pair of round holes onto the lugs. In general, however, the leveling protrusions and recesses or holes for them can have any shape. In the case of using a single leveling projection, its cross-section is preferably non-round in order to ensure a clear position, and the corresponding recess or opening then has a corresponding, non-round, shape.

A plurality of light sources may be attached to the support frame, preferably via a printed circuit board or heatsink, in a unique position defined by at least one pair of complementary alignment elements. The first member of each of these pairs includes a recess and the second member of each pair includes a projection fitting into the recess on the first member of the pair. One element of each pair is attached to the support frame and the other is attached to the set of light sources. Advantageously, the protrusion of the complementary balancing element narrows towards its free end and/or the recess on the second complementary balancing element widens towards its open end, i.e. the entrance to the recess. This ensures their reliable seating.

Preferably, the protrusion of the complementary alignment element comprises at least two arms and the recess of the second element comprises at least two slots in which the arms are clamped. More preferably, there are three arms, for example in the shape of T or Y. Inserting the arms into the slots ensures the mutual centering of both elements from the pair, so that the relative position of the set of light sources and the supporting frame is precisely determined. In the case where the protrusions are implemented with arms, the protrusion preferably includes at least three arms and the recess includes at least three slots for clamping the arms. Expanding the projection and/or narrowing the recess can then be realized by increasing the thickness of the arms and/or reducing the width of the slots. Preferably, the arms intersect in the center of the projection, in the case of a single arm, this arm preferably passes through the center of the projection.

The relative position of the silicon optical element and the support frame can be defined by a non-empty set of protrusions on the silicon optical element fitting into complementary recesses on the support frame and/or a non-empty set of protrusions on the support frame fitting into complementary recesses on the silicon optical element. The position of the silicone optical element on the support frame does not have to depend only on the pressure of the mounting frame, but can also be defined directly by the silicone optical element, which further refines the alignment of all the components of the lamp. Particularly advantageously, the recesses on the silicon optical element can be aligned with the push protrusions, so that the protrusions on the support frame fitting into these recesses for defining the position of the silicon optical element at the same time advantageously press with their pressure surfaces on the push protrusions for aligning the printed circuit board.

The shortcomings of the solutions known from the state of the art are further removed to a certain extent by the method of manufacturing a lamp for a car, which includes the following steps:

• Insertion of the silicon optical element into the opening for the passage of light in the supporting frame;

- 4 CZ 2022 - 146 A3 • Deposition of the silicon optical element with the mounting frame, whereby the protrusions for the light input of the silicon optical element pass through the passages for stabilizing the protrusion on the mounting frame after dismounting. These two steps can also take place in the opposite order or both at the same time.

• Attaching the mounting frame to the support frame, whereby the silicon optical element lowered with the mounting frame is pressed to the support frame by the mounting frame; and • Attaching a plurality of light sources to a support frame with the attachment frame attached, each light source of the plurality being aligned with a corresponding light entry protrusion and protrusion stabilization passage.

The lamp according to the invention, as defined above, is particularly advantageously produced by this method of production. The method can then, for example, further include the step of mutual alignment of the set of light sources and the support frame using at least one pair of complementary alignment elements.

Preferably, the method further comprises the steps of:

• Bonding the printed circuit board carrying the set of light sources to the heatsink; and • Aligning the printed circuit board before curing the adhesive by pressing at least one push tab of the silicon optical element between the printed circuit board and the support frame. These steps occur prior to attaching the array of light sources to the support frame.

As described above, the use of push lugs in any of their forms will prevent the circuit board from curling, which could cause a decrease in the luminosity of the resulting lamp. Preferably, the shape and distribution of the push-out protrusion or protrusions is as described for the lamp according to the invention above, in particular, the push-out protrusions are preferably distributed around the light sources for the most even alignment of the printed circuit board at the location of the light sources.

The step of attaching the attachment frame to the support frame may include defining the relative position of the frames by interlocking at least one protrusion or recess on the attachment frame with at least one recess or protrusion on the support frame. In particular, this protrusion can be a leveling protrusion, as described for the lamp according to the invention. It is also possible to align both frames in the method according to the invention with an alignment protrusion, which is a separate part, while both frames include an opening or recess for an alignment protrusion. A set of light sources is particularly advantageously aligned with the frames by the aligning projection.

Clarification of drawings

The essence of the invention is further clarified by examples of its implementation, which are described using the attached drawings, where on:

Fig. 1 is a schematic diagram of an exploded view of some of the components of the lamp according to the invention, namely the support frame, the silicon optical element and the mounting frame, while a pair of pins on the support frame are used to align these components with each other, on which the mounting frame is placed through a pair of holes, while the silicone optical element is clamped between the frames and its projections for the light input pass through the passages for stabilizing the projection of the mounting frame, Fig. 2 is a schematic view of the cross-section of the lamp according to the invention, the plane of the section being parallel to the direction of light emission from the light sources and from flashlights, so it is noticeable

- 5 CZ 2022 - 146 A3 mounting of frames with a silicon optical element and a printed circuit board carrying light sources not shown here, Fig. 3 is a schematic representation of a simplified cross-sectional view of a lamp according to the invention, while the cross-sectional plane is also parallel to the direction of light emission and passes through the pair LED light sources and a corresponding pair of protrusions for light entry, as well as a pair of push protrusions clamped between the printed circuit board carrying the LED and the supporting frame, Fig. 4 shows in perspective two complementary balancing elements before they fit into each other, Fig. 5 shows a view of the complementary leveling elements from Fig. 4 after they have been removed from each other, whereby the front view of one arm of the T-protrusion clamped in the gap of the second element is particularly visible, Fig. 6 is a more detailed perspective view of the attachment frame from Fig. 1, Fig. 7 is a more detailed perspective view of the silicon optical element from Fig. 1 and Fig. 8 is a flowchart for the method of manufacturing a lamp for a car according to the present invention.

Examples of implementation of the invention

The invention will be further explained by examples of implementation with reference to the respective drawings.

The subject of the present invention is a lamp for cars. This lamp includes a supporting frame 1, a silicon optical element 2, a mounting frame 3 for fixing the silicon optical element 2 and a circuit board 10 equipped with an array of LED light sources 4 and a heatsink 9. This lamp can be, for example, a front lamp of a car or its part, e.g. dipped beam or contour light, but it can also be a rear lamp, direction light, etc.

The supporting frame 1 is the main supporting element of the lamp supporting the other components. An opening for the passage of outgoing light is defined in it, while a silicone optical element 2 is inserted into this opening from behind, and a secondary optical element, in particular a cover glass, can be placed on it from the front. Furthermore, the supporting frame 1 contains a number of connecting and defining elements to ensure the exact centering of other components of the lamp, as will be described below. The opening for the passage of exiting light is provided near its rear edge with a flange 14, on which the silicon optical element 2 rests. This flange 14 includes five rearward-facing protrusions terminated at the rear end, in contact with the silicon optical element 2, with pressure surfaces 13, which will described in more detail below in connection with the pushing protrusions 11 of the silicon optical element 2.

The silicone optical element 2 includes a body 5 ending on the front side with a surface for light exit, which is located inside the support frame 1 after inserting the element into the hole in the support frame 1, and further includes a field of protrusions 6 for the input of light. Each protrusion 6 for light input serves to collimate and homogenize light from one light source 4 and has a free end attached to the light source 4 and the opposite end opening into the body 5. The shape of the silicon optical element 2 corresponds to the shape of the opening for the passage of outgoing light in the supporting frame 1 , in Fig. 1 this shape is approximately rectangular, but in general it can be essentially arbitrary. After the lamp has been removed, the silicone optical element 2 rests on the flange 14 of the support frame 1, while the protrusions of the flange 14 pass through the recesses on the edges of the silicon optical element 2, thereby defining the exact mutual position of both components. In the embodiment shown, these recesses are located under the push protrusions 11, but in general their position, shape and number can be essentially arbitrary and in some embodiments they do not have to be on the silicon optical element 2 at all. The material of the silicon optical element 2 does not have to be clean

- 6 CZ 2022 - 146 A3 silicone, it can be a silicone-based material containing other components. In general, another material with comparable properties, especially the optical properties, heat resistance and flexibility of silicone, can be used for the optical element.

The attachment frame 3 serves to press the silicone optical element 2 to the support frame 1 and to stabilize the protrusions 6 for the entrance of light. The fixing frame 3 can be made of a metal plate and includes an array of passages 7 for stabilizing the protrusion, the number and distribution of which corresponds to the number of protrusions 6 for the input of light and light sources 4. When lowered, each protrusion 6 for the input of light passes through a corresponding passage 7 to stabilize the protrusion towards the corresponding source 4 of light. At the same time, the protrusion can be in close contact with the source, but there can also be an air gap between them. In Figure 3, the passages are shown to be significantly larger than the cross-section of the protrusions at a given location for clarity, but preferably the protrusions abut the edges of the passages so that the protrusions are fixed in a precise location.

To attach the mounting frame 3 to the support frame 1, with the silicone optical element 2 between them, for example, flexible mounts 15 with holes located on the mounting frame 3 for catching the protrusions on the support frame 1 can be used. In Fig. 1, five flexible mounts 15 and a pair of protrusions on the outer surface of the upper wall defining an opening for the passage of the emerging light on the support frame 1. The other three of these protrusions are on the lower surface of this wall, so they are not visible in Fig. 1. In some embodiments, these protrusions may be on the inner surface of this wall. In other embodiments, for example, the flexible grips 15 can fit into complementary holes on the supporting frame 1. In other embodiments, the attachment frame 3 does not have to include the flexible grips 15.

Alignment projections 8 are also used to define the exact position between the two frames. Due to the flexibility of the flexible projections 15, their attachment does not have to ensure a completely precise position, so the lamp advantageously contains additional alignment elements. The compensating protrusions 8 can, for example, take the form of a pair of pins or pins, e.g. in the shape of a truncated pyramid, located on the support frame 1 and pointing backwards, i.e. against the direction of light emission from the lamp. The mounting frame 3 then includes a pair of holes for mounting on these pins. One of these holes can be round and the other oval in order to allow them to be fitted onto the pins in the exact position despite possible minor inaccuracies. In general, the shape, number and location of these leveling protrusions 8, and thus also the openings for them, can be essentially arbitrary. They can therefore be, for example, angular or have a T, X, Y, V cross-section, etc., they can be placed above each other instead of next to each other, etc. The height of the leveling protrusions 8 on the support frame 1 can be significantly lower than in fig. 1, for example, it can correspond to the thickness of the material of the fastening frame 3. The fastening frame 3 does not have to be fitted to the leveling protrusions 8 through through holes, but for example through cutouts on the side, non-through holes, etc.

The compensating projections 8 can, alternatively or in addition, be located on the mounting frame 3, with complementary openings or recesses on the supporting frame 1. Alternatively or additionally, the compensating projections 8 can be on another part of the lamp, e.g. on the heatsink 9 or the printed circuit board 10, or they can be separate parts. Both frames can then include holes or recesses for mounting on such leveling projections. The silicone optical element 2 can also include holes or recesses for the passage of alignment protrusions 8. In general, any elements on any component of the lamp can be used as alignment protrusions 8, which allow at least the support frame 1 to be aligned with the attachment frame 3 and preferably prevent their mutual displacement , as well as their mutual filming.

The printed circuit board 10 with the light sources 4 and the heat sink 9 is attached to the supporting frame 1, preferably with screw connections, but it is possible to use, for example, gluing, welding, riveting or a fixed shape connection, for example, with plastic snap elements. Advantageously, the printed circuit board 10, and possibly also the heatsink 9, contains holes or recesses for the passage of leveling projections 8. The leveling projections 8 then define the position of not only the frames, but also the set of light sources 4 on the printed circuit board 10. Alternatively, the printed circuit board 10 or the cooler 9 may contain the compensating protrusions 8.

- 7 CZ 2022 - 146 A3

Advantageously, the precise alignment of the printed circuit board 10 and the heat sink 9, or alternatively the set of light sources 4 realized in a different way, with respect to the supporting frame 1 is further ensured by means of several pairs of complementary aligning elements 12. Each of these pairs includes one element with a projection and a second element with a complementary recess for precise engagement of this projection. One element of the pair is located on the support frame 1 and the other is located on the set of light sources 4, especially on the printed circuit board 10 or on the heatsink 9.

For example, the lamp includes one pair of complementary alignment elements 12, and this pair includes a projection with a "T" cross-section (T-projection) on one element (here on the support frame 1), and a raised portion defining a gap adapted to receive the projection with a cross-section of " T” on the second element (here on the 10 PCB). The compensating element defining the gap has the form of a cylinder in the illustrated embodiment, which is firmly connected to the printed circuit board 10 at the first end and three cut-outs are formed into it at the second, free end, tapering towards the first end. These cutouts are rotated by 90° around the axis of this leveling element, respectively. 180° so that one shoulder of the projection with a "T" cross-section on the second leveling element of the given pair can fit into each cut-out. Due to the tapered shape of the cut-out, the arms of the T-prong are clamped when inserting one leveling element into the other (see Fig. 4 and 5) and at the same time this shape pushes the center of the T-prong into the center of the gap during insertion, so that the set of 4 light sources when assembled exactly aligned with the supporting frame 1. The gap therefore has the largest cross-sectional area at the point of entry into the gap and gradually narrows further.

In Fig. 5, one arm of the complementary compensating element 12 is visible in the form of a T-prong fixed between two approaching walls of the cutout in the compensating element on the printed circuit board 10. As can be seen in this picture, the arm of the T-port tapers downwards, i.e. towards the free end of the T-port. In alternative embodiments, the thickness of the arms of the T-port may be constant throughout the height of the T-port, since the corresponding cutouts are sufficient to fit and clamp the arms firmly. An embodiment where some arms taper and others do not is also possible, in such an embodiment all cutouts on the second alignment element may taper correspondingly, or the cutouts corresponding to the tapering arms may have a constant width.

In the assembly, which will be described in more detail in the method according to the invention below, the set of light sources 4 is seated with the support frame 1, with the compensating element with T-protrusion behind the frame passing through the gap defined by the walls of the compensating element on the printed circuit board 10 as far as possible tapering cutouts forming these gaps. In some embodiments, the T-protrusion or a differently shaped complementary compensating element 12 can also form any or every compensating projection 8 and can thus also pass through the hole in the mounting frame 3.

Instead of the shape of the letter T, the complementary leveling elements 12 can have protrusions and possibly cut-outs of essentially any shape. Particularly advantageous is the shape of the cross-section of the protrusions comprising a series of straight arms, where at least some arms are divergent with respect to other arms. Advantageously, these arms intersect in the middle of the cross-section. Clamping of arms or similar elements on these protrusions may not, in some embodiments, occur on the perimeter of the gaps defined by the second compensating element, as is the case, for example, in Fig. 4 and 5, but may, for example, also occur in the middle of these gaps.

The connection of the printed circuit board 10 to the cooler 9 is advantageously realized by gluing. In the state of the art with these glued joints, bulges, undulations or other inaccuracies can occur on the printed circuit board 10, which cause minor deviations in the location or direction of the individual LED light sources 4. According to the present invention, these inaccuracies are advantageously avoided thanks to the push protrusions 11 provided on the silicon optical element 2. The push protrusion 11 can be any protruding part of the optical element that is clamped between the support frame 1 and the printed circuit board 10, so that the support frame 1 flexibly pushes 10 printed circuit boards onto the board. Preferably, the push protrusion 11 passes along a larger part, e.g. at least half, more preferably at least three quarters, of the circumference of the silicon optical element 2, or this element includes multiple push

- 8 CZ 2022 - 146 A3 protrusions 11 distributed around the perimeter, especially around protrusions 6 for the entry of light. As a result, the supporting frame 1 presses the printed circuit board 10 evenly around the light sources 4, thereby ensuring its alignment in the area of the light sources 4.

In Fig. 1, the silicon optical element 2 includes five push protrusions 11, while the mounting frame 3 includes cutouts on the periphery through which the push protrusions 11 pass into contact with the printed circuit board 10. The above-mentioned protrusions on the flange 14, into which the cutouts on the circumference of the silicon optical element 2 fit for its alignment on the supporting frame 1, at the same time support the pushing protrusions 11 from the front with their pushing surfaces 13. In some embodiments, the pushing protrusion 11 can pass through the entire circumference of the silicon optical element 2, whereby the flexible mounts 15 can pass, for example, through openings provided in the optical element or the attachment frame 3 can be attached to the support frame 1 in a different way. In other embodiments, on the other hand, the silicon optical element 2 may include a larger number of push protrusions 11, e.g. up to ten or up to twenty, etc. The number and distribution of the push protrusions 11 depends in particular on the shape and size of the printed circuit board 10.

In Fig. 2 and 3 it is in section, respectively in cross-section, showing the mutual arrangement of the components of the lamp. In particular, it can be seen from Fig. 3 that the silicon optical element 2 rests on the flange 14, its protrusions 6 for the entrance of light pass through the passages 7 for stabilizing the protrusion in the fixing frame 3 to the light sources 4 and that its push protrusions 11 are clamped between the support frame 1 and a printed circuit board 10, with the protrusions 6 for the entrance of light being arranged between the push protrusions 11. The cross-section of Fig. 3 is taken across the mounting frame 3 in the place of two opposite cut-outs for the push protrusions 11, unlike the section of Fig. 2, which it corresponds to the design from Fig. 1 and its section is guided by one cut-out and one flexible handle 15. It is also evident from Fig. 3 that, on the resulting lamp, the light sources 4 are exactly aligned with the protrusions 6 for the input of light and with the passages 7 for stabilizing the protrusions.

The subject of the invention is also a method of manufacturing a lamp for a car, e.g. the lamp described in any embodiment above. This method includes the following steps:

• Placing the silicon optical element 2 in the opening for the passage of the outgoing light in the supporting frame 1;

• Deposition of the silicon optical element 2 with the mounting frame 3, whereby the protrusions 6 for the light input of the silicon optical element 2 pass through the passages 7 to stabilize the protrusion on the mounting frame 3 after dismounting. These first two steps can also take place in the opposite order, so that into the support frame 1 the silicon optical element 2 is then placed already removed with the mounting frame 3, and both can take place at the same time;

• Attaching the mounting frame 3 to the supporting frame 1, whereby the silicon optical element 2, which is lowered with the mounting frame 3, is pressed against the supporting frame 1 by the mounting frame 3. For example, in Fig. 1, the entire circumference of the silicon optical element 2 is pressed between the frames, except for parts of the circumference with by the push protrusions 11, which are not in contact with the mounting frame 3, so that they can push the printed circuit board 10; and • Attaching a plurality of light sources 4 to a support frame 1 with a mounting frame 3 attached, each light source 4 of the plurality being aligned with a corresponding protrusion 6 for light entry and passage 7 for stabilization of the protrusion.

Even the step of attaching the set of light sources 4 can take place at the same time as some of the steps mentioned above before it. For example, the printed circuit board 10 with the heatsink 9 glued can be placed on the alignment projections 8 and/or the complementary alignment elements 12 even before the frames are joined together. The engagement of the flexible grips 15 behind the protrusions on the support frame 1 can only occur due to the approach of the printed circuit board 10 to the support frame 1, whereby the fastening frame 3 is pushed to the support frame 1 and at the same time the protrusions 6 for the entry of light can be pushed into the passages 7 to stabilize the protrusions.

- 9 CZ 2022 - 146 A3

Advantageously, this attachment of the set of light sources 4 is realized by means of a printed circuit board 10, to which the light sources 4 are firmly connected, e.g. by soldering or gluing, etc., or by means of its cooler 9. The connection to the supporting frame 1 can be realized, for example, by gluing or welding and preferably by screwing together. Instead of the printed circuit board 10, any other structural element carrying the light sources 4 can be used, so that it is not necessary to attach the light sources 4 individually, although this is also possible in principle.

Advantageously, the method further comprises the steps of:

• Sticking the printed circuit board 10 carrying the set of light sources 4 to the heatsink 9; and • Aligning the printed circuit board 10 before the adhesive cures by pressing at least one push protrusion 11 of the silicon optical element 2 between the printed circuit board 10 and the support frame 1.

These optional steps ensure that the printed circuit board 10 remains flat and the adhesive between the printed circuit board 10 and the heatsink 9 also remains flat, so that there is no displacement or rotation of the light sources 4, which would result in a decrease in the luminance of the lamp. The step of gluing the printed circuit board 10 to the heat sink 9 can occur at any time during this method, it preferably occurs before its attachment to the support frame 1. Particularly advantageously, after the end of the method, the printed circuit board 10 is pressed between the heat sink 9 (or the adhesive on the heat sink 9) and the push protrusions 11, whereby the flatness of the printed circuit board 10 is ensured during the curing of the glue, e.g. several days. The push protrusions 11 push the printed circuit board 10 even after the glue has hardened, but at that moment there is no longer a standard danger of the glue bulging, so this pressure is no longer necessary to maintain the flatness of the printed circuit board 10.

The step of attaching the attachment frame 3 to the support frame 1 preferably includes defining the mutual position of the frames by mutually fitting at least one protrusion (i.e. alignment protrusion 8) or recess on the attachment frame 3 into at least one recess or protrusion on the support frame 1. Similar to the above-described lamp, it can furthermore, the alignment of the frames must be ensured by fitting the alignment projection 8, which is a separate part or is attached to another component, for example the cooler 9, into recesses or holes on both frames.

During the attachment of the set of light sources 4 to the support frame 1, the alignment of these components, which also ensures the alignment of the individual light sources 4 with the protrusions 6 for the input of light and the passages 7 for stabilizing the protrusion, is ensured by means of complementary alignment elements 12, for example as described in lamps according to the invention above. One element from each pair can be part of the support frame 1 and the other part of the set 4 of light sources, especially its cooler 9. After this alignment, the attachment is then carried out, for example by screwing.

An example of the method according to the invention is described by the flow chart shown in Fig. 8. In this example, the silicon optical element 2 is first inserted into the mounting frame 3, so that the protrusions 6 for the input of light pass through the passages 7 for stabilizing the protrusions. Subsequently, the silicone optical element 2 is inserted through the surface for light output on the body 5 into the supporting frame 1, while it remains inserted into the mounting frame 3. At the same time, both frames are aligned thanks to the alignment protrusions 8, and in the case of using flexible mounts 15, after alignment and seating of both frames and the optical element to fit the flexible grips 15 behind the protrusions on the support frame 1 and all three components are thus held together in the exact position determined by the alignment protrusions 8. Subsequently, the printed circuit board 10 with the heat sink 9 is aligned with the frames by means of the complementary alignment element 12 i silicone optical element 2 and is attached to the supporting frame 1, e.g. screwed. At the same time, the support frame 1 presses on the printed circuit board 10 through the pressure projections 11 and thus keeps it level until the glue hardens.

The method according to the invention can be modified with regard to any embodiment of the lamp according to the invention. For example, when placing the silicon optical element 2 in the hole, it can

- 10 CZ 2022 - 146 A3 in the support frame 1, the silicon optical element 2 fits onto the flange 14, whereby the protrusions on the flange 14 or elsewhere on the support frame 1 can fit into complementary recesses on the element and/or vice versa, the protrusions on the silicon optical element 2 can fit into the recess on the support frame 1, thereby ensuring the exact position of the silicon optical element 2. The attachment frame 3 is preferably attached to the support frame 1 by flexible attachments 15, but any other attachment is also possible.

The compensating protrusions 8 can have essentially any shape and distribution, suitable for ensuring the relative position of the components. The number and shape of the push protrusions 11 can also be essentially arbitrary, and there are also possible designs where there are no push protrusions 11.

Claims (10)

1. A lamp for an automobile, which includes a support frame (1), a silicon optical element (2), a mounting frame (3) and a set of light sources (4) comprising at least two light sources (4), wherein the silicon optical element (2) includes the body (5) provided with a surface for light output and further a silicon optical element (2) for each light source (4) from a set of light sources (4) includes a projection (6) for light input, with the free end of the projection pointing towards the given source (4 ) of light, and wherein the mounting frame (3) includes for each projection (6) for light input a passage (7) for stabilizing the projection, wherein each projection (6) for light input passes through a given passage (7) for stabilizing the projection from the body (5 ) towards the corresponding source (4) of light, characterized in that the lamp further includes at least one leveling projection (8), while the attachment frame (3) is attached to the supporting frame (1) in a position defined by at least one leveling projection (8) , which is seated in a recess on one frame from the attachment frame (3) and the support frame (1), while the leveling projection (8) is further seated in a recess on the second frame from this pair or is attached to the second frame from this pair, while the silicon optical element (2) is clamped between the mounting frame (3) and the support frame (1). 2. A lamp for a car according to claim 1, characterized in that the set of light sources (4) includes a heatsink (9) and a printed circuit board (10) on which the light sources (4) are located, wherein the printed circuit board (10) it is glued to the radiator (9) and attached to the supporting frame (1). 3. A lamp for a car according to claim 2, characterized in that the silicon optical element (2) includes at least one push protrusion (11) for aligning the printed circuit board (10), wherein the push protrusion (11) is clamped between the board (10) printed circuit boards and the supporting frame (1), while the printed circuit board (10) is pushed to the cooler (9) by the pusher protrusion (11). 4. A lamp for a car according to any one of claims 2 to 3, characterized in that the silicon optical element (2) includes a plurality of push-in protrusions (11) for aligning the printed circuit board (10), wherein the push-in protrusions (11) are distributed around the protrusions (6) for light input. 5. A lamp for a car according to any one of claims 2 to 4, characterized in that the leveling projection (8) is attached to the support frame (1) and passes through the attachment frame (3) into a recess in the printed circuit board (10). 6. A lamp for a car according to any one of the preceding claims, characterized in that the set of light sources (4) is attached to the support frame (1) in a unique position defined by at least one pair of complementary alignment elements (12), wherein the first element of each pair comprises a recess and the second element of each pair comprises a projection fitting into the recess on the first element of the pair, one element of each pair being attached to the support frame (1) and the other being attached to the set of light sources (4). 7. A lamp for a car according to any one of the preceding claims, characterized in that the relative position of the silicone optical element (2) and the support frame (1) is defined by a non-empty set of protrusions on the silicon optical element (2) fitting into complementary recesses on the support frame ( 1) and/or by a non-empty set of protrusions on the support frame (1) fitting into complementary recesses on the silicon optical element (2). 8. A method of manufacturing a lamp for a car, characterized in that it includes the following steps: • insertion of the silicon optical element (2) into the opening for the passage of light in the supporting frame (1); • dismounting the silicon optical element (2) with the mounting frame (3), whereby the projections (6) for the light input of the silicon optical element (2) pass through the passages (7) for stabilizing the projection on the mounting frame (3); • attachment of the attachment frame (3) to the support frame (1), whereby the silicone optical element (2) lowered with the attachment frame (3) is pressed to the support frame (1) by the attachment frame (3); and • attaching the set of light sources (4) to the support frame (1) with the attached attachment - 12 CZ 2022 - 146 A3 by the frame (3), whereby each source (4) of light from this set is aligned with the corresponding projection (6) for the entrance of light and the passage (7) for stabilization of the projection. 9. The method of manufacturing a lamp for a car according to claim 8, characterized in that it further includes the steps: 5 • gluing of the circuit board (10) carrying the set of light sources (4) to the cooler (9); and • aligning the printed circuit board (10) before the adhesive cures by pressing at least one push protrusion (11) of the silicon optical element (2) between the printed circuit board (10) and the support frame (1). 10. The method of manufacturing a lamp for a car according to any one of claims 8 to 9, characterized in that the step of attaching the mounting frame (3) to the supporting frame (1) includes defining the relative position of the frames by interlocking at least one protrusion or recess on the mounting frame ( 3) with at least one recess or protrusion on the support frame (1).