DE102012204605B4 - Method for producing a light guide body and light guide body - Google Patents

Abstract

A method (100) for producing a light guide body (10, 54), the light guide body (10, 54) having a light coupling surface (42, 46), a light coupling out surface (52) and at least one deflection section (16), light being transmitted via the light coupling surface ( 42, 46) can be coupled into the light guide body (10, 54), can be reflected on the deflection section (16) and can be decoupled on the light extraction surface (52), characterized in that in a first production step (102) a deflection body (12) in an injection molding process (104) is made of plastic with a mirror-like mirror surface (14) which at least partially forms the deflecting section (16), the deflecting section being designed as a prism area having a plurality of deflecting prisms and a glass body in a second production step (112) (22) made of transparent material (24) is injected onto the deflecting body (12) in such a way that it surrounds at least the at least one deflecting section (16) This means that the deflecting body (12) is connected to the glass body (22) by means of undercut sections (36, 40) provided on the deflecting body (12).

Description

The invention relates to a method for producing a light guide body according to the preamble of claim 1 and a light guide body according to the preamble of claim 9. Such a method and such a light guide body are from the US 2005/0189 545 A1 known. Further light guide bodies are from the DE 100 21 725 A1 and the DE 43 29 914 A1 known.

From the DE 100 22 779 A1 a light guide body is known in which light is coupled into a light guide rod and continues to run under total reflection in the light guide until the light hits a decoupling prism. There the light is deflected with total reflection and then leaves the light guide on the light decoupling surface opposite the decoupling prism. Due to the total reflection condition prevailing in these light guides, the outcoupling direction of the light is partially in the same direction as the light rays also have in the light guide. This means that most of the light is decoupled "forwards".

From the DE 10 2005 059 958 A1 a lighting device for motor vehicles is now known, which deals with this problem of the “forward” decoupled light. A light decoupling to the rear or "backwards" is in the DE 10 2005 059 958 A1 solved in that the angles of the light decoupling elements or decoupling prisms are chosen so that at least part of a light incident on a second deflecting side of a first decoupling element can be transmitted through this under refraction and can be coupled back into the light guide on a first deflecting side of a subsequent decoupling element. This light is then at least partially guided from the first to the second deflecting side of a further decoupling element and deflected by means of this second deflecting side in the direction of the decoupling surface. In this way it can be achieved that at least a small part of the light can be coupled out to the rear or “backwards”. This area of the light, which can be coupled out to the rear, is very narrow and limited by the geometry and by the total reflection.

In order to be able to decouple the light against the arrow of a light guide, ie “backwards”, the deflecting surfaces of the decoupling prisms can now be mirrored. In this context, sweep is understood to mean the inclination of the headlights or light guide bodies with respect to the longitudinal axis of the vehicle, with this sweeping often being unavoidable for design reasons. In order to mirror the decoupling prisms, which are for example vapor-coated with aluminum in special chambers, the sections of the light guide which are not to be mirrored can be masked with a cover material. After the aluminum has been vaporized onto the coupling prisms, this cover material can then be removed again. The decoupling prisms then no longer work according to the principle of total reflection, rather light is reflected on the mirrored decoupling prisms. However, due to the size of the light guides and the sometimes very complex structure of the light guides, it is very difficult to mask the light guides with the cover material before they are mirrored. On the one hand, the masking of the sections that are not to be mirrored requires considerable effort, on the other hand only a few parts fit into the vapor deposition chambers and the vapor deposition of the light guides takes a lot of time.

Another disadvantage of this procedure is that clean edges cannot easily be realized with the cover material. The covering material must be applied very precisely and close precisely on edges in particular. If the covering material is not applied precisely in the edge area but, for example, in a wavy manner, the uncleanliness of the adjoining mirror section is further increased by the magnifying glass effect of the light guide cross-section.

It is also known in the case of collimators or so-called slit light guides to utilize the principle of total reflection in transparent bodies. However, a large area which is totally reflective is always followed by a transmitting area where light losses can occur. To avoid these light losses, it would also be advantageous here to also mirror at least the area of the light guide or collimators that is effective in transmission, so that the collimator does not have any high light losses. However, the collimators would also have to be masked in a complex manner with a cover material before the vapor deposition, since the light coupling-in surfaces and the light coupling-out surfaces must not be mirrored.

A well-known problem with light guides and collimators is that all surfaces of the light guide are optically effective due to the principle of total reflection that is often used there. It is therefore difficult to attach fastening and / or stiffening elements to the light guides or collimators without the optical effectiveness of the light guide or collimator being impaired, since otherwise the optics could be disturbed by the add-on and / or fastening elements.

The invention is therefore based on the object of providing light guide bodies in an inexpensive and reliable manner, with light in one The largest possible area should be able to be coupled out and the efficiency of the light guide should be increased.

This object is achieved by a method for producing a light guide body with the features of claim 1 and by a light guide body with the features of claim 9. To produce a light guide body with a light coupling surface, a light coupling surface and at least one deflecting section, light being coupled into the light guide body via the light coupling surface, reflecting on the deflecting section and decoupling on the light coupling surface, it is provided that in a first manufacturing step a deflecting body with a mirror-like mirror surface which forms the deflecting section at least in sections, and wherein in a second production step a glass body made of transparent material is injected onto the deflecting body in such a way that it encloses at least the at least one deflecting section.

The manufacture of a deflecting body with a mirror-like mirror surface in a first manufacturing step with subsequent overmolding with transparent material has proven to be particularly advantageous compared to the prior art because it is possible to dispense with complex masking of the light guide body with cover material before applying a mirror layer. In the second production step, the glass body made of transparent material is sprayed onto the already mirrored deflecting body that forms the deflecting section.

In particular, the deflecting body can have a closed, mirror-like mirror surface.

Because the deflecting section is designed as a prism area having a multiplicity of prisms, the light can also be coupled out in a larger angular range in comparison to the prior art, even against the arrow of the light guide.

With so-called collimators, too, the light losses in transmitting areas can be avoided, since the entire mirrored deflecting section can now have a reflective effect and no longer have any transmitting areas.

The fastening and stability problems in light guide bodies, as they are known from the prior art, can also be avoided in this way. The deflecting body produced in the first manufacturing step with a closed mirror-like mirror surface makes it possible to arrange fastening elements and / or stiffening elements on this deflecting body, since the entire deflecting body has a closed mirror surface. The fastening and / or stiffening elements are therefore not optically effective, since they are not visible to the light coupled into the glass body.

According to the invention, the deflecting body is produced from plastic in an injection molding process. This proves to be advantageous since complicated structures of the deflecting body can also be produced in an injection molding process. Mass production of the deflecting body is also easily possible in an injection molding process.

It proves to be particularly advantageous if the mirror-like mirror surface is applied to the deflecting body in the form of a metal layer and / or a multilayer coating. In such a multilayer coating, several low and high refractive index layers are alternately combined with one another. Such a metal layer can be applied, for example, using various coating technology methods. For example, it can be provided that the metal layer is applied by sputtering, magnetron sputtering, vapor deposition or, for example, by what is known as plasma polymerization. Of course, other methods of metallic coating technology are also conceivable.

An alternative not according to the invention provides that the deflecting body is produced from metal by a primary forming and / or a machining process. It can then be provided that the mirror surface is produced by polishing the deflecting body produced by the primary forming and / or machining process in the first step. In the production of the deflecting body by a primary forming and / or a cutting process from metal, the step of vapor deposition or sputtering can then be dispensed with. The mirror-like mirror surface is created solely by polishing the deflecting body.

It is also advantageous if, in an intermediate step between the first manufacturing step and the second manufacturing step, the deflecting body is sealed with a transparent layer. This transparent layer can, for example, improve the adhesion between the deflecting body and the glass body. Furthermore, the mirror surface can be protected against corrosion by applying the transparent layer. It is also possible to increase the reflectivity of the mirror surface by applying the transparent layer by applying the transparent layer.

The transparent layer is advantageously made of organic lacquers, Silicon hydrogen, quartz layers, ormocers or organosilicon materials are produced.

According to the invention it is provided that the deflecting body is connected to the glass body by means of rear grip sections provided on the deflecting body. This is particularly advantageous because the glass body injection-molded onto the deflecting body in the second manufacturing step then engages behind the deflecting body at the rear grip sections in such a way that the deflecting body is inextricably connected to the glass body.

Another advantageous embodiment of the invention provides that the mirror-like surface is made from a metal, preferably from aluminum, silver, platinum, gold, nickel, chromium, copper, tin and / or from alloys of at least one of these metals. This proves to be advantageous because these metals have a particularly high reflectivity.

It is also advantageous if the transparent material is an organic glass or a silicone rubber.

It is particularly advantageous if the organic glass is polycarbonate PC, polymethyl methacrylate PMMA, cycloolefin polymer COP, cycloolefin copolymer COC, polymethacrylmethylimide PMMI or polysulfone PSU. These organic glasses prove to be particularly advantageous for the production of the light guide body.

The transparent material and / or the transparent layer advantageously contain organyl titanium. These titanium organyls can influence the refractive indices of the transparent material and / or the transparent layer. It is particularly advantageous if the refractive index of the transparent layer is smaller than the refractive index of the glass body.

The light guide body according to the invention has, inter alia, a light input surface, a light output surface and at least one deflection section, wherein light can be coupled into the light guide body via the light input surface, can be reflected on the deflection section and can be decoupled on the light output surface, the light guide body being a deflection body with a mirror-like mirror surface, which is at least partially forms the deflection section, and comprises a glass body made of transparent material which encloses at least the at least one deflection section.

Such a light guide body is, as already mentioned above, particularly advantageous, since disadvantages of light guide bodies as they are known from the prior art can be avoided.

On the one hand, with such a light guide body it becomes possible that more light can be coupled out “backwards”, that is to say against the arrow of the light guide body. On the other hand, a complicated masking of the areas which do not form the deflection section can be avoided before any mirroring.

In particular, such a light guide body is produced according to the method according to the invention.

Fastening and / or stiffening elements are advantageously arranged on the side of the deflecting body facing the deflection section. Because of the closed, mirror-like mirror surface, it can be achieved that the deflection body can be fastened, for example, in the headlight housing. The stiffening elements for stabilizing the deflecting body can also be arranged on the deflecting body without the propagation of the light in the light guiding body being disturbed by them, since the fastening and / or stiffening elements cannot hinder the propagation of the light in the light guiding body.

Furthermore, it is advantageous if the light guide body is a collimator and / or an optical attachment and / or a lens array.

According to the invention, the deflecting section is designed as a prism area having a plurality of deflecting prisms. Through the prism area having a plurality of deflecting prisms, light can be deflected in a targeted manner so that it can be decoupled on the light decoupling surface in a certain direction, preferably against the arrow of the light guide body in the direction of travel.

A lens array not according to the invention has a light coupling-in surface, a light coupling-out surface and at least one funnel-shaped deflecting section, wherein light can be coupled into the lens array via the light coupling-in surface, can be reflected on the deflecting section and can be coupled out on the light coupling-out surface, the lens array having a deflecting body with a mirror-like mirror surface, which is at least partially forms the funnel-shaped deflecting section and comprises a glass body made of transparent material which encloses at least the at least one funnel-shaped deflecting section.

The deflection section can advantageously be designed as a funnel-shaped outlet of the lens array. This proves to be particularly advantageous since the deflecting body can now first be produced in the form of a negative of the lens array using the method according to the invention. The deflector with the closed mirror-like mirror surface can then be encapsulated with a glass body made of transparent material.

Since such lens arrays have so far been made of silicone, they have a low rigidity. Due to the rigidity of the deflecting body, the glass body can now be made from a temperature-resistant silicone, for example, without the rigidity being negatively affected. Due to the increased rigidity of the lens array, which can be achieved by the deflecting body, the manageability of the lens array suitable for production can be increased. Such lens arrays can thus be easily integrated into LED headlight systems.

• 1 Eine schematische Darstellung des Ablaufs eines erfindungsgemäßen Verfahrens;
• 2 eine mögliche Ausführungsform eines Umlenkkörpers eines erfindungsgemäßen Lichtleitkörpers;
• 3 einen erfindungsgemäßen Lichtleitkörper in einer perspektivischen Darstellung;
• 4 den Lichtleitkörper nach 3 in einer Seitenansicht;
• 5 den Lichtleitkörper gemäß 3 und 4 in einer Seitenansicht von rechts;
• 6 eine Ausführungsform eines nicht erfindungsgemäßen Linsenarrays; und
• 7 eine perspektivische Darstellung eines Glaskörpers eines nicht erfindungsgemäßen Linsenarrays.

Further details and advantageous embodiments of the invention can be found in the following description, on the basis of which the embodiments of the invention shown in the figures are described and explained in more detail. Show it:

• 1 A schematic representation of the sequence of a method according to the invention;
• 2 a possible embodiment of a deflection body of a light guide body according to the invention;
• 3 a light guide body according to the invention in a perspective view;
• 4th the light guide body 3 in a side view;
• 5 the light guide body according to 3 and 4th in a side view from the right;
• 6th an embodiment of a lens array not according to the invention; and
• 7th a perspective view of a glass body of a lens array not according to the invention.

1 shows the course of a procedure 100 to manufacture one for example in the 3 until 5 illustrated light guide body 10 . In a first step 102 becomes an in 2 shown deflection body 12th with a closed mirror-like mirror surface 14th manufactured. The mirror surface 14th forms a deflection section at least in sections 16 . The deflector 12th can be done in the first production step 102 either in an injection molding process 104 be produced, in a subsequent step 106 the mirror-like mirror surface 14th on the in 2 shown deflection body 12th in the form of a metal layer 18th or a multilayer coating 20th is applied. In the case of such a multilayer coating, alternating layers of low and high refractive index are combined with one another. However, it is also possible that in the first step 102 the deflector 12th by a primary forming and / or a cutting process 108 is made with the mirror surface 14th of the deflector 12th then by polishing 110 of the deflector 12th arises.

In a second production step 112 then becomes one in the 3 until 5 illustrated glass body 22nd made of transparent material 24 so on the deflector 12th injected that at least the deflection section 16 is completely enclosed. At the end of the process 100 stands, also in the 3 until 5 illustrated, finished light guide body 10 .

Between the first production step 102 and the second manufacturing step 112 can in an intermediate step 114 the deflector 16 with an in 2 illustrated transparent layer 26th be sealed. This transparent layer 26th consists preferably of organic lacquers, or silicon hydrogen, of quartz layers, ormocers or organosilicon materials.

The mirror-like mirror surface 14th consists advantageously of a metal, preferably of aluminum, silver, platinum, gold, nickel, chromium, copper, tin and / or of alloys of one or more of these metals.

The transparent material 24 of the vitreous 22nd is advantageously an organic glass or a silicone rubber. This organic glass is, for example, a polycarbonate PC, a polymethyl methacrylate PMMA, cycloolefin polymer COP, cycloolefin copolymer COC, polymethacrylmethylimide PMMI or polysulfone.

The transparent material 24 and / or the transparent layer 26th can contain so-called titanium organyls. These titanium organyls influence the refractive indices of the transparent layer 26th and the transparent material 24 . Here is the refractive index of the transparent layer 26th preferably less than the refractive index of the transparent material 24 of the vitreous 22nd .

2 shows a deflection body 12th a light guide body 10 how he dealt with the procedure 100 after 1 , step there 102 will be produced. This deflector 12th has a deflection section 16 on which as a variety of prisms 28 having prism area 30th is trained. The prism area 30th or the prisms 28 Fastening or stiffening elements are turned away 32 arranged so that these are not optically effective, as the entire deflection body 12th with the mirror-like mirror surface 14th is covered. Therefore, there is no refraction but only reflection and light reaches the fastening or stiffening elements 32 not. These fastening or stiffening elements 32 are preferably integral with the Deflection body 12th educated. On the narrow sides 34 of the deflector are the prisms 28 averted rear grip sections 36 intended. On the broadsides 38 of the deflector 12th are also rear grip sections 40 arranged.

3 shows a light guide body 10 how he dealt with the procedure 100 after 1 will be produced. After making the deflector 12th In the first step 102 becomes the deflector with the transparent material 24 of the vitreous 22nd overmoulded in the second step. The vitreous 22nd engages behind the on the deflection body 12th arranged rear grip sections 36 , 40 . This is in the side view after 4th for the rear grip sections 36 clearly visible. In 5 is are the rear grip sections 40 shown. Because of these back-grip sections 36 , 40 the connection of the in 2 shown deflector 12th with the one in the 3 until 5 shown glass body 22nd . The fastening or stiffening elements 32 protrude so far from the vitreous 22nd out that the fastening or stiffening elements 32 not completely from the vitreous 22nd be enclosed. The prism area 30th , which at the light guide body 10 according to 3 until 5 as a deflection section 16 is made entirely of the transparent material 24 of the vitreous 22nd enclosed.

The light guide body 10 points on its narrow side 41 at least one light coupling surface 42 on. On the narrow side 41 opposite narrow side 44 can also have an additional second light coupling surface 46 be provided. At these light coupling surfaces 42 , 46 can light from a light source, not shown, into the light guide body 10 are coupled. The broadsides 49 of the light guide body 10 can do it like from the DE 100 22 779 A1 known as defocusing faces 50 be trained. These side faces 50 are then for example concave. However, it is also conceivable that the side surfaces 50 are straight or convex. This is in 5 each shown in dashed lines. The cross section of the light guide body 10 increases in the direction of the light output surface 52 , with the side faces 50 to the light output surface 52 connect.

If now light over the light coupling surfaces 42 , 46 in the light guide body 10 , or in the vitreous 22nd of the light guide body 10 is coupled in, takes place on the broad sides 49 or on the defocusing side surfaces 50 a total reflection. When the rays of light hit the prisms 28 of the deflection section 16 hit, they are there due to the closed mirror-like mirror surface 14th reflected. This reflection on the deflector 12th or on the mirror surface 14th is not limited by the total reflection, as the deflection body 12th or the mirror surface 14th is mirrored. In this way it can be achieved that in the light guide body 10 or in the vitreous 22nd coupled light can also be coupled “backwards”, ie against the arrow of the light guide body. This represents an improvement on the out of the DE 10 2005 059 958 A1 known light guide body.

4th shows the light guide body 10 the end 3 in the side view on the broad sides 49 . The two light coupling surfaces are there 42 , 46 as well as the light output surface 52 recognizable.

5 shows the side view of one of the two narrow sides 41 , 44 of the light guide body 10 . The defocusing, conical side surfaces 50 of the vitreous 22nd are clearly visible. The deflector 12th is on the light output surface 52 remote side of the vitreous 22nd arranged.

6th shows a lens array 54 as it can be arranged in front of LED arrays, for example. Lens arrays described in the prior art have so far been made from silicone. Such a lens array is for example in FIG DE 10 2009 053 581 B3 disclosed. The entire revelation of the DE 10 2009 053 581 B3 should therefore also belong to the disclosure of the present invention.

In contrast to the lens array known from the prior art, in the case of the lens array 54 how it looks 6th is known to produce the method 100 according to 1 can be applied. For the sake of simplicity, the corresponding reference numerals from FIG 1 until 5 used.

7th shows an example of a glass body 22nd of a lens array according to the invention 54 . This vitreous 22nd is for the sake of clarity without the associated deflection body 12th shown. When using the procedure 100 can be a lens array 54 getting produced. In the first production step 102 the deflector 12th like him in 6th is shown as a negative form 56 the optically effective elements 58 manufactured. The manufacture of the deflector 12th can be done as above under 1 has already been described.

At the second step 112 then become the vitreous 22nd the optically effective elements 58 in the negative form 56 of the lens array 54 injected. The transparent material 24 this vitreous 22nd or the optically effective elements 58 encloses at least part of the two as a deflection section 16 trained side surfaces 60 of the deflector 12th . Because of the mirror-like mirror surface 14th of the deflector 12th is in the vitreous humor 22nd or in the optically effective elements 58 via the light coupling surface 42 light that can be coupled into the glass body 22nd of the lens array 54 coupled in and in contrast to the prior art, the light is on the mirrored side surfaces 60 the optically effective elements 58 not totally reflected. Because of the mirrored side surfaces 60 there is a reflection of the light.

The light then appears, as in the DE 10 2009 053 581 B3 has been described, after repeated reflection on the light output surface 52 , what a 6th on the light coupling surface 42 facing away from the glass body 22nd the end. Through the deflector 12th can stiffen the lens array 54 can be achieved in such a way that the manageability of the lens array can be increased enormously, especially in the production area for mounting in vehicle headlights. The shape of the lens arrays 54 there are no or hardly any limits. Any number of optical elements can be used 58 to be arranged both in the horizontal and in the vertical direction.

7th shows a vitreous body 22nd a lens array 54 . This is in 7th without the one in the first production step 102 manufactured deflection body 12th shown. The multitude of optically effective elements 58 and the associated light coupling surfaces 42 and light decoupling surfaces 46 are in 7th shown.

Claims (12)

A method (100) for producing a light guide body (10, 54), the light guide body (10, 54) having a light coupling surface (42, 46), a light coupling out surface (52) and at least one deflection section (16), light being transmitted via the light coupling surface ( 42, 46) can be coupled into the light guide body (10, 54), can be reflected on the deflection section (16) and can be decoupled on the light extraction surface (52), characterized in that in a first production step (102) a deflection body (12) in an injection molding process (104) is made of plastic with a mirror-like mirror surface (14) which at least in sections forms the deflecting section (16), the deflecting section being designed as a prism area having a plurality of deflecting prisms and a glass body in a second production step (112) (22) made of transparent material (24) is injected onto the deflecting body (12) in such a way that it has at least one deflecting section (16) and so on It is concluded that the deflecting body (12) is connected to the glass body (22) by means of undercut sections (36, 40) provided on the deflecting body (12). Method (100) according to Claim 1 , characterized in that the mirror-like mirror surface (14) is applied to the deflecting body (12) in the form of a metal layer (18) and / or a multilayer coating (20). Method (100) according to one of the preceding claims, characterized in that in an intermediate step (114) between the first manufacturing step (102) and the second manufacturing step (112) the deflecting body (12) is sealed with a transparent layer (26). Method (100) according to Claim 3 , characterized in that the transparent layer (26) is made from organic lacquers, silicon hydrogen, quartz layers, ormocers or organosilicon materials. Method (100) according to one of the preceding claims, characterized in that the mirror-like mirror surface (14) is made of a metal, preferably aluminum, silver, platinum, gold, nickel, chromium, copper, tin and / or alloys of at least one of these metals will be produced. Method (100) according to one of the preceding claims, characterized in that the transparent material (24) is an organic glass or a silicone rubber. Method (100) according to Claim 6 , characterized in that the organic glass is polycarbonate PC, polymethyl methacrylate PMMA, cycloolefin polymer COP, cycloolefin copolymer COC, polymethacrylmethylimide PMMI or polysulfone PSU. The method (100) according to any one of the preceding claims, characterized in that the transparent material (24) and / or the transparent layer (26) according to one of the Claims 4 until 7th Titanium organyle included. Light guide body (10, 54), wherein the light guide body (10, 54) has a light coupling surface (42, 46), a light outcoupling surface (52) and at least one deflection section (16), with light entering the light guide body via the light coupling surface (42, 46) (10, 54) can be coupled in, can be reflected on the deflection section (16) and can be coupled out on the light extraction surface (52), characterized in that the light guide body (10, 54) is formed by a deflection body (12) made of plastic in an injection molding process and having a mirror-like mirror surface (14), which at least partially forms the deflecting section (16), and a glass body (22) made of transparent material (24) which encloses at least the at least one deflecting section (16), the deflecting section being formed as a plurality of deflecting prisms having prism area is formed and wherein the deflecting body (12) with the glass body (22) by means of behind-grip sections (36, 40) provided on the deflecting body (12) connected is. Light guide body (10, 54) after Claim 9 , characterized in that fastening and / or stiffening elements (32) are arranged on the side of the deflection body (12) facing away from the deflection section (16). Light guide body (10, 54) according to one of the Claims 9 or 10 , characterized in that the light guide body (10, 54) is a collimator and / or an auxiliary lens and / or a lens array. Light guide body (10, 54), characterized in that the light guide body (10, 54) according to one of the methods (100) of Claims 1 until 8th is made.

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