DE102013225949A1 - Motor vehicle headlamps - Google Patents

Abstract

A motor vehicle headlight (10) with at least one semiconductor light source (14) and a primary optics (16) which is set up to collect light emanating from the semiconductor light source (16) and direct it to a secondary optics (18), the primary optics (16) being presented. the light of the light source (14) via a light entry surface (26) receives and decouples via a light exit surface (28) and wherein the primary optics (16) has a Anbindungsflansch (42) with which they in a holder (34) in at least two fixed bearings ( 52) disposed in a first plane which is parallel and at a distance (a) to a second plane in which the light entry surface lies. The motor vehicle headlight is characterized in that a first section (44) of the connecting flange (42) is domed.

Description

The present invention relates to a motor vehicle headlight having the features of the preamble of claim 1.

Such a motor vehicle headlight is from the DE 10 2010 023 359 A1 known. The known headlamp has at least one semiconductor light source and one primary optic, which is set up to collect light emanating from the semiconductor light source and to direct it to secondary optics. The primary optics absorbs the light from the light source via at least one light entry surface and couples it out via a light exit surface. The primary optics has a connection flange with which it is held on a holder in at least two fixed bearings, which are arranged in a first plane which lies parallel and at a distance from a second plane in which the at least one light entry surface lies. The light exit surface of semiconductor light sources used for motor vehicle headlights is typically in a rectangle with an edge length of between 0.5 and 2 millimeters. In order to receive the largest possible part of the light emitted by the semiconductor light sources, the distance of the light exit surface of the semiconductor light source from the light entry surface of the primary optics is only a few tenths of a millimeter. The length of the primary optic, which lies between its light entry surface and its light exit surface, is typically a few millimeters. It is, for example, in a range of 5 to 15 mm, this range is only to illustrate typical size ratios and in other examples may be outside the specified limits.

Semiconductor light sources reach temperatures of over 100 ° C during operation. Due to the closely adjacent arrangement of the semiconductor light sources and the primary optics results in a thermal coupling, which can lead to a heating of the primary optics and thus to a change in distances within the headlamp by thermal component expansion. Further temperature influences on such distances result from the surroundings of the headlight. Automotive technology achieves headlight ambient temperatures that can exceed 100 ° C. This is especially true when installed in the vicinity of an internal combustion engine of a motor vehicle. In cold weather, the ambient temperatures can also assume high values in the negative range.

It has been shown that the resulting large temperature differences can exert undesirable effects on light-technical headlamp characteristics such as the coupling-in and / or the coupling-out efficiency and thus can adversely affect the light distribution and thus also the fulfillment of legal requirements or customer requirements. In addition, it has been found that with narrow gaps between light exit surfaces of semiconductor light sources and light entry surfaces of primary optics, mechanical damage to the semiconductor light sources can occur.

A reduction of the distance between the light exit surface of the semiconductor light sources and the light entry surface of the primary optics may, for example, lead to an undesired mechanical contact of these surfaces and thus to a damage of the semiconductor light source.

The known headlight compensates the thermal expansion of the primary optics by an oppositely acting thermal expansion of the holder, however, has the disadvantage that the relevant dimensions of the primary optics and the holder must be the same in order to achieve complete compensation of the thermal expansion of the primary optics. This means that the length of the thermally expanding holder with the same coefficient of expansion must correspond to the distance between the light entrance surface and the light exit surface of the primary optics. In reality, the first level (fixed storage level) is usually at a distance from the second level (light entry area level). As a rule, the light entry surfaces are only arranged at a very small distance from the light sources, in order to couple in as much of the light emanating from the light sources into the primary optics. However, it is not possible to arrange the fixed bearing directly at the height of the light exit surfaces. This is because the boards on which the light sources are arranged, in addition to the light sources and the tracks, which serve to provide electrical power to the light sources, have other, usually electronic components, which have a certain height, with which they via the light sources protrude. It is therefore often not possible to arrange the bearings of the holder in the plane in which the light exit surfaces of the light sources are located.

Against this background, the object of the invention in the specification of a motor vehicle headlamp, in which a holder of the primary optics is designed so that the thermal change in length of the primary optics between the light entrance surface and light exit surface is as completely as possible compensated without the bearings of the holder are in the same plane like the light entry surface of primary optics.

The object is achieved by a motor vehicle headlight with the features of claim 1.

The headlight according to the invention is characterized in that a first portion of the Anbindungsflansches, which is located between a part held in the fixed bearing part of the Anbindungsflansches and the light exit surface, dome-like, wherein the light exit surface is located on the convex side of the curvature.

The dome-like bulge of the first section and the fixation of the primary optic between two fixed bearings cause the primary optic to bulge when thermally induced by primary optic expansion between the two fixed bearings. The curvature results from the fact that a central area of the primary optics expands between the fixed bearings due to an increase in temperature, while a distance between the two fixed bearings only slightly or ideally does not change due to a different coefficient of linear expansion of the bearing having bearing.

Due to the stress build-up in the plane of the clamping, the expansion is forced in the direction of the dome shape, so that the clamped between the fixed bearings part bulges further. As a result, the central area moves away from the light sources, drawing with it the light entering ends of the primary optics which adjoin the central area. As a result, the light entry surfaces, which delimit the light entry ends in the direction of the light sources, are moved away from the light sources, so that an approach of the light entry surfaces of the primary optics to the light exit surfaces of the semiconductor light sources resulting from a thermally induced change in the length lying between the light entry surfaces and the light exit surface Primary optics is compensated.

Furthermore, it is proposed that the primary optic is made of silicone. Silicone is a highly transparent material and has a high temperature resistance. Some silicones are particularly thin in the production phase and can be sprayed during the injection molding in extremely filigree structures, which is advantageous for the production of thin optical fiber ends.

A further embodiment provides that the connection flange is made of the same material as the primary optics. Silicone, for example, an elastic material that is good form and / or non-positively fixed in the holder, even if the holder has manufacturing tolerances.

In addition, it is proposed that the connection flange is integrally connected to the primary optics. As a result, the primary optics and the connection flange can be produced together in one process step cost-effectively as a one-piece component by injection molding.

Furthermore, it is proposed that the connection flange is designed to run around the light exit surface of the primary optics. The peripheral connection flange has the advantage that a translation of the primary optics in two spatial directions is positively blocked by mechanical stop of the connection flange to the bracket.

A further embodiment provides that the holder has a receptacle and an insert, wherein the receptacle is positively and / or positively connected to the insert. Between the receptacle and the insert of the Anbindungsflansch the primary optics is fixed in force and / or positively fixed in the holder. The non-positive and / or positive connection is realized for example as a screw, through which the insert is connected to the receptacle. By the screw connection in particular a clamping force is generated with which the primary optics is fixed non-positively in the holder. With such a holder designed in a simple manner two fixed bearings can be realized with which the primary optics is held on a basic structure of the headlamp.

In addition, it is proposed that the receptacle and the insert have a smaller coefficient of linear expansion than the primary optics. Thus, with a temperature change, the distance between the two fixed bearings changes to a lesser extent than the volume or the length of the primary optics between the two fixed bearings. This ensures that the primary optic bulges when the temperature rises.

Furthermore, it is proposed that the first section is received in a gap between the receptacle and the insert, wherein the gap is wider than the material thickness of the first section. This gap gives room to the bulge of the primary optics. As a result of the bulge, the light entry surfaces of the primary optics move away from the light exit surfaces of the semiconductor light sources.

A further embodiment provides that the receptacle has a recess in which a light entry end of the primary optics is received. The recess forms a kind of guide, which permits a movement of the light entry end perpendicular to the light exit surface of the semiconductor light source, but blocks movements of the light entry surface of the primary optics transversely to the surface normal of the light entry surface.

Furthermore, it is proposed that the light entry end, viewed from the light entry surface, has an increasing cross section. The increasing with increasing distance from the light entrance surface cross-section causes a desired reduction of the opening angle of the propagating light in the primary optics, so that the light exits in bundled form through the light exit surface of the primary optics in the direction of a possibly but not mandatory secondary optics of the headlamp.

In addition, it is proposed that a cross-section of the light entry end extends abruptly, as seen from the light entry surface, so that a first abutment surface is created, which cooperates with a second abutment surface, which is a component of the holder. The two abutment surfaces together form a mechanical stop, which prevents a collision of the light entry surface with the light source at large thermally induced changes in length of the primary optics.

It is also preferred that the light sources are arranged on a carrier element. The carrier element is part of the mounting structure and serves for fastening the semiconductor light sources to the base structure. In addition to the light sources, further electronic components and printed conductors are arranged on the carrier element, which serve to supply energy and / or control the light sources.

A further embodiment provides that the headlamp has a plurality of semiconductor light sources arranged in the manner of a matrix and a primary optic which is designed as an optical array with a plurality of matrix-like and optically active elements. In this case, the optically active elements concentrate the light emanating from the semiconductor light sources and direct it to the secondary optics arranged downstream in a beam path. In particular, when a length of the secondary optics transverse to the beam path is small compared to a length of the primary optics in this direction, the primary optics are preferably curved in a horizontal plane in the case of intended use. The curvature is concave, as seen from the secondary optics, so that the light decoupled from the primary optics is focused on the secondary optics. This concave curvature of the primary optics, which is concave in the horizontal plane, is not influenced by the curvature according to the invention which is convex from the viewpoint of secondary optics, since the profile of the convex curvature preferably lies in a vertical plane due to suitable arrangement of the fixed bearings.

Further advantages will be apparent from the dependent claims, the description and the attached figures.

It is understood that the features mentioned above and those yet to be explained below are applicable not only in the particular combination given, but also in other combinations, without departing from the scope of the present invention.

Embodiments of the invention are illustrated in the drawings and are explained in more detail in the following description. In this case, the same reference numerals in the various figures denote the same elements. It branches, each in schematic form:

1 a motor vehicle lighting device according to the prior art in a sectional view as the environment of the invention;

2 a primary optics of a motor vehicle headlight according to the invention and a holder for the primary optics in a sectional view;

3 a detailed view of a light module in a sectional view;

4 an arrangement of a secondary optics and a primary optics for an embodiment of the motor vehicle headlight according to the invention.

The 1 shows a sectional view of a motor vehicle headlight 10 with a light module 12 , In other embodiments, the headlight 10 also several light modules 12 exhibit. The light module 12 has semiconductor light sources 14 , a primary optic 16 and a secondary optics 18 on. The light module 12 is in a housing 20 of the headlight 10 arranged. The housing 20 has a light exit opening, that of a transparent cover 22 is covered.

The light sources 14 are on a support element 24 arranged. On the carrier element 24 are next to the light sources 14 arranged further electrical components and interconnects, which provide an electrical supply and control of the light sources 14 allow, which is not shown here for reasons of clarity. The carrier element 24 is usually a rigid or flexible board and is usually in thermal contact with a heat sink, not shown in the figure, which is arranged and arranged, which in an operation of the light sources 14 to absorb the resulting heat and release it to the environment. Each of the semiconductor light sources 14 has a respective individual light exit surface 17 on.

The primary optics 16 is adapted to from the light exit surfaces of the light sources 14 to collect outgoing light and to the secondary optics 18 to judge. This is indicated by primary optics 16 Light entry surfaces 26 on. Through the light entry surfaces 26 each light enters one of the light sources 14 in each case a light entry end 27 the primary optics 16 one. The distance d1 between the light exit surfaces of the light sources and the light entry surfaces of the finger-like light entry ends 17 The primary optic is only a few tenths of a millimeter in size and can be influenced by the linear expansion of the components. The primary optic expands with increasing temperature stronger than the holder 34 , contact with primary optics and light sources can occur, which must be avoided at all costs. The light entry end 27 points from the light entry surface 26 her views on an increasing cross-section. The light entry end 27 directs the light by total internal reflection in the direction of a light exit surface 28 , Through the light exit surface 28 the light gets out of primary optics 16 decoupled.

The secondary optics 18 is designed to light that over the light exit surface 28 from primary optics 16 is decoupled, record and direct in a rule-compliant light distribution in the apron of the headlamp and thus in particular on a lying in front of the vehicle lane.

At this point, a thought Cartesian coordinate system is introduced, which is for the 1 and all subsequent figures have validity. The x-axis of the coordinate system points in the direction of a main light exit direction 30 of the headlight 10 and thus in the apron of the vehicle. The y-axis points in the 1 into the plane of the drawing and the z-axis points in the 1 up. The y-direction is preferably aligned parallel to a transverse axis of the vehicle in a proper use of the headlamp in the vehicle. The z-axis is preferably aligned parallel to the vertical axis.

The light module 12 has support structures, by means of which the at least one semiconductor light source 14 , the primary optics 16 and the secondary optics 18 on a base structure 32 are attached. In the illustrated embodiment, the support structures on three separate parts, namely the carrier element 24 with which the semiconductor light sources 14 at the base structure 32 are attached, a bracket 34 the primary optics 16 and a holder 36 the secondary optics 18 , Based on the following 2 becomes the operation of a features of the invention comprising holder 34 the primary optics 16 explained in more detail.

2 shows a sectional view of a primary optic 16 and her bracket 34 , The cutting plane is parallel to the xz plane. In this embodiment, the holder 34 primary optics has two elements. The first element is a recording 38 , which with the basic structure 32 connected is. The basic structure 32 corresponds functionally to the basic structure 32 from the 1 and is in the 2 not shown for reasons of clarity. The second element is an insert 40 , which is positively and / or non-positively connected to the recording. Between the recording 38 and the mission 40 is a connection flange 42 the primary optics 16 arranged. The connection flange 42 is preferably integral with the primary optics 16 connected.

Preference is given to primary optics 16 made of silicone. Silicone is a highly transparent material and has a high temperature resistance up to approx. 260 ° C. Certain types of silicone are particularly thin in the production phase and can be sprayed into filigree structures as part of an injection molding process. Silicone is also an elastic material. Due to the elasticity, the primary optics 16 good frictional in the holder 34 be accommodated, manufacturing tolerances of the holder can continue 34 be well balanced, so that a primary optics by means of the connection flange 42 exactly in relation to the light sources position. Due to the above-described properties of the material, it is preferable that the connection flange 42 and the primary optics 16 Made of silicone. Particularly preferred is the production of primary optics 16 and connection flange 42 as an integral component, for example by injection molding. In other embodiments are the primary optics 16 and / or the connection flange 42 made of glass, plastic or a technically comparable material.

The connection flange 42 has two first sections 44 on that in the 2 above and below the light exit surface 28 connect directly to this. The first sections 44 are dome-shaped arched. From the location of the light entry surfaces 26 From the perspective of the curvature of the first sections 44 concave. At these first sections 44 closes in each case a second, vertical section 46 at. It should be noted that the terms "vertical" and "horizontal" with respect to the intended use of the headlight in the motor vehicle. In the 2 and the following figures, therefore, the term "vertical" an extension in the direction of the z-axis and the term "horizontal" an extension in the direction of the x-axis and / or the y-axis. The vertical section 46 lies perpendicular to the main emission direction 30 , At these vertical sections 46 closes in each case a third, horizontal section 48 at. The third sections 48 extend from the second sections 46 starting perpendicular to these in the main emission direction 30 ,

The two horizontal sections 48 lie respectively on designated areas 50 of the second mission 40 so that in the 2 upper surface 50 the use of a movement of the upper horizontal section 48 the primary optics blocked down and the lower surface 50 the use of a movement of the lower horizontal section 48 the primary optics blocked upwards. The horizontal sections 48 and the surfaces 50 So work together so that a translation of the primary optics 16 is blocked in the vertical direction.

The two vertical sections 46 the primary optics are between the intake 38 and the mission 40 through a perpendicular to the vertical sections 46 acting clamping force fixed. The clamping force is generated by the fact that the recording 38 and the use 40 by means of a non-positive and / or positive connection, such as by a screw connection 49 , are connected so that the vertical sections 46 the primary optic between the admission 38 and the mission 40 be trapped. Clamping the vertical sections 46 initially prevents a translation of the primary optics 16 in the direction of the x-axis. With a sufficiently large clamping force is also a movement of the vertical sections 46 and thus a translation of the primary optics 16 prevented in the direction of the y-axis by adhesion.

The positive locking of the horizontal sections 48 the primary optics through the surfaces 50 of the insert 40 and between the insert 40 and the recording 38 non-positive and positive fixation of the vertical sections 46 The primary optics prevent a translation of the primary optics 16 in three directions. To the translation of the primary optics 16 In addition, in the direction of the y-axis to prevent by positive engagement, the connection flange is preferably performed circumferentially. Also conceivable is a mechanical stop in the direction of the y-axis.

From a purely mechanical point of view, the sections form 48 the primary optics and the surfaces 50 of the insert and the fixed by the clamping forces vertical sections 46 the primary optics with respect to the x-direction and the y-direction an upper and a lower fixed bearing 52 in which the primary optics 16 in the holder 34 is held. The two camps 52 lie in a first level 100 , The first level 100 is in the 2 perpendicular to the plane of the drawing and lies parallel to a second plane 102 in which the light entry surfaces 26 the primary optics 16 lie. The first plane and the second plane have a distance a, which in any case is so great that on the carrier element 24 arranged components 104 which rise higher from there than the light source 14 , no mechanical contact with the mechanical components of the second level 100 have lying fixed storage.

At a temperature increase in the headlight 10 the primary optic expands 16 between the two fixed camps 52 out. Due to different expansion coefficients of primary optics 16 and bracket 34 the mount expands 34 less strong. Therefore, the distance between the upper and lower fixed bearings changes 52 not or at least less than the length of the fixed camps 52 trapped primary optic 16 , Under these conditions, this change in length leads to a bulge of the primary optic 16 in X direction. A central area 53 the primary optics 16 moves in the x direction and pulls the light entry ends 27 the primary optics, located at the central area 53 connect in the x direction, from the light exit surfaces of the semiconductor light sources 14 path. This will approximate the light entry surfaces 26 the primary optics 16 to the light exit surfaces of the semiconductor light source 14 , which is caused by a thermally induced elongation of the primary optics, compensated in part.

The domed shape of the first sections 44 sets the direction of the bulge.

The dome-shaped sections 44 lie in a gap 56 between the recording 38 and the mission 40 , The width of the gap 56 is slightly larger than the material thickness of the dome-shaped section 44 , so that there is a gap. This space gives the bulge space.

In an advantageous embodiment, the materials that make up the recording 38 and the use 40 are manufactured, a much smaller coefficient of linear expansion, as the material from which the connection flange 42 is made. This occurs with a temperature change during recording 38 and the mission 40 a lower elongation or shrinkage than at the connection flange 42 , As a desired consequence remain the positions of the fixed bearing 52 with respect to the housing 20 preserved as far as possible.

At one in the 2 embodiment shown has the recording 38 recesses 58 on. In the recesses 58 are the light entry ends 27 the primary optics 16 added. The recesses 58 act in the drawing plane like guides or floating bearings. That is, the recesses 58 allow a translation of the primary optics 16 in the x direction and at the same time prevent translation of the light entry ends 27 in the direction of the z-axis and preferably also in the direction of the y-axis. Due to the light-outlet-side bulge are in the primary optics 16 light entry side induced compressive stresses along the z-direction. These compressive stresses cause, especially in primary optics 16 which, like the embodiment shown here, has several light entry ends 27 have that the light entry surfaces would be moved on an arc around the y-axis against each other. The pictures of the light entering ends 27 in the recesses 58 prevent these shifts of the Light entry surfaces 26 because they are the possibilities of movement of the light entering ends 27 limit.

The 3 shows a detail of the light module 12 in the area of the light entry surface 26 , In this area, the light entry end 27 the primary optics 16 a return 60 on. That is, in the direction of the light entry surface 26 considered takes the cross section of the light entry end 27 abruptly. The primary optic dilates 16 due to a temperature rise, the return may be 60 to a stop surface 62 create, which is attached to the base structure. The stop surface 62 and the return 60 are arranged and arranged, the thermally induced movement of the light entry end in the direction of the semiconductor light source, here by an arrow 64 symbolized by a mechanical stop 14 to limit. This creates the risk of a collision of the light entry surface 26 the primary optics 16 with the semiconductor light source 14 prevented.

The 4 shows the primary optic 16 and the secondary optics 18 a headlight 10 , In this embodiment, the headlight 10 a plurality of semiconductor light sources arranged in matrix fashion 14 on, from which emanates light. In a beam path of the semiconductor light sources 14 outgoing light is the primary optic 16 arranged. The primary optics 16 is as an optic array 66 with a plurality of optically active elements arranged in the form of a matrix 68 designed. The optically active elements 68 bundle this from the semiconductor light sources 14 outgoing light and direct it to the arranged in the beam path secondary optics 18 , For secondary optics 18 whose dimensions are small compared to a longitudinal extent of the optical array 66 , it is known, the optics array 66 in a horizontal plane when used as intended from a secondary optics point of view 18 to curve concave. This will focus the light on the secondary optics 18 and / or the arched Petzval area of secondary optics 18 reached. The above described, from the secondary optics 18 seen convex curvature of the primary optics 16 which completely compensates for a longitudinal expansion of the optical elements 68 serves, finds in such an optical array 66 also application. The arched first sections 44 are doing on the long sides above and below the optics array 66 arranged. The light exit surfaces of the individual optimally effective elements of the optic array 66 executed primary optics 16 are each preferably curved in a vertical plane. The concave curvature of the optic array 66 in the horizontal plane remains unaffected.

QUOTES INCLUDE IN THE DESCRIPTION

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Cited patent literature

• DE 102010023359 A1 [0002]

Claims (13)

Motor vehicle headlights ( 10 ) with at least one semiconductor light source ( 14 ) and a primary optic ( 16 ) which is adapted from the semiconductor light source ( 14 ) to collect outgoing light and to secondary optics ( 18 ), with primary optics ( 16 ) the light of the light source ( 14 ) via at least one light entry surface ( 26 ) and via a light exit surface ( 28 ) and the primary optics ( 16 ) a connection flange ( 42 ), in which it is in a holder ( 34 ) in at least two fixed camps ( 52 ), which are arranged in a first plane which is parallel and at a distance (a) to a second plane in which the at least one light entry surface lies, characterized in that a first section (FIG. 44 ) of the connection flange ( 42 ), which is located between a part of the Anbindungsflansches held in the fixed bearing and the light exit surface, dome-like curved, wherein the light exit surface ( 28 ) lies on the convex side of the curvature. Motor vehicle headlights ( 10 ) according to the preceding claim 1, characterized in that the primary optics ( 16 ) is made of silicone. Motor vehicle headlights ( 10 ) according to one of the preceding claims, characterized in that the connecting flange ( 42 ) is made of the same material as the primary optic ( 16 ). Motor vehicle headlights ( 10 ) according to one of the preceding claims, characterized in that the connecting flange ( 42 ) in one piece with primary optics ( 16 ) connected is. Motor vehicle headlights ( 10 ) according to one of the preceding claims, characterized in that the connecting flange ( 42 ) is executed circumferentially. Motor vehicle headlights ( 10 ) according to one of the preceding claims, characterized in that the holder ( 34 ) a recording ( 38 ) and an insert ( 40 ), wherein the receptacle ( 38 ) with the use ( 40 ) is positively and / or positively connected. Motor vehicle headlights ( 10 ) according to one of the preceding claims, characterized in that the receptacle ( 38 ) and the use ( 40 ) have a smaller coefficient of linear expansion than the primary optics ( 16 ). Motor vehicle headlights ( 10 ) according to one of the preceding claims, characterized in that the first section ( 44 ) in a gap ( 56 ) between the recording ( 38 ) and the mission ( 40 ), the gap ( 56 ) is greater than the material thickness of the first section ( 44 ). Motor vehicle headlights ( 10 ) according to one of the preceding claims, characterized in that the receptacle ( 38 ) a recess ( 58 ), in which a light entry end ( 27 ) of primary optics ( 16 ) is recorded. Motor vehicle headlights ( 10 ) according to one of the preceding claims, characterized in that the light entry end ( 27 ) from the light entry surface ( 26 ) ago seen an increasing cross-section. Motor vehicle headlights ( 10 ) according to one of the preceding claims, characterized in that a cross section of the light entry end ( 27 ) from the light entry surface ( 26 ) seen expanded suddenly, so that a first stop surface ( 60 ), which with a second stop surface ( 62 ) cooperates. Motor vehicle headlights ( 10 ) according to one of the preceding claims, characterized in that the light sources ( 14 ) on a carrier element ( 24 ) are arranged. Motor vehicle headlights ( 10 ) according to one of the preceding claims, characterized in that the headlight ( 10 ) a plurality of semiconductor light sources arranged in the form of a matrix ( 14 ) and a primary optic ( 16 ) configured as an optical array ( 66 ) with a plurality of optically active elements arranged in the form of a matrix ( 68 ), wherein the optically active elements ( 68 ) that of the semiconductor light sources ( 14 ) bundle outgoing light and onto the secondary optics arranged in a beam path ( 18 ) judge.

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