EP1637798B1 - Beleuchtungs- und/oder Signaleinrichtung Reflektor für Fahrzeugen - Google Patents

Beleuchtungs- und/oder Signaleinrichtung Reflektor für Fahrzeugen Download PDF

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Publication number
EP1637798B1
EP1637798B1 EP05291920A EP05291920A EP1637798B1 EP 1637798 B1 EP1637798 B1 EP 1637798B1 EP 05291920 A EP05291920 A EP 05291920A EP 05291920 A EP05291920 A EP 05291920A EP 1637798 B1 EP1637798 B1 EP 1637798B1
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EP
European Patent Office
Prior art keywords
reflector
polymer
arithmetic mean
fibres
reflective coating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP05291920A
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English (en)
French (fr)
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EP1637798A1 (de
Inventor
Gilles Viard
Julien Carboneil
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Valeo Vision SAS
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Valeo Vision SAS
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Publication of EP1637798A1 publication Critical patent/EP1637798A1/de
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Publication of EP1637798B1 publication Critical patent/EP1637798B1/de
Not-in-force legal-status Critical Current
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/30Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by reflectors
    • F21S41/37Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by reflectors characterised by their material, surface treatment or coatings
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V7/00Reflectors for light sources
    • F21V7/22Reflectors for light sources characterised by materials, surface treatments or coatings, e.g. dichroic reflectors
    • F21V7/28Reflectors for light sources characterised by materials, surface treatments or coatings, e.g. dichroic reflectors characterised by coatings

Definitions

  • the present invention relates to reflectors intended to be incorporated in lighting or signaling devices for motor vehicles, such as projectors or lights.
  • the invention is more particularly concerned with reflectors based on polymer (s). Its purpose is to develop polymer-based reflectors with improved optical properties. In the alternative, its purpose is to develop reflectors of this type having a simplified / easy method of obtaining.
  • the invention firstly relates to a reflector intended to equip a lighting or signaling device for a motor vehicle and comprising a structure based on polymer (s) covered at least partly with a reflective coating, said structure also comprising fibers.
  • Fibers are understood to include elements having an elongated shape, and for example a length at least 10 times, especially at least 100 or 1000 times greater than what can be assimilated to its diameter when dealing with a form fiber approximately cylindrical. These fibers are advantageously of a different nature than that of the polymer structure in which they are located.
  • the invention thus discovered that incorporating a fibrous material into the polymeric structure of the reflector was feasible and extremely advantageous for more than one reason.
  • the presence of these fibers makes it possible in fact to modify in a controlled manner the surface state of the polymer structure before being covered with the reflective coating: it makes it possible to select the level of surface roughness such as the metallic coating, "next »This roughness, will be able to reflect the rays emitted by the light source with a wide angular distribution.
  • this surface modification due to the presence of the fibers did not have a significant negative impact (within the limit of a mass concentration of fibers of less than about 50%) on the low light absorption of the reflector once provided with its reflective coating.
  • said structure is covered by the reflective coating, either directly or via one or more layers of low total thickness, generally less than 50 nm, especially less than 10 nm obtained by a vacuum deposition process (less than 0.01 Mbar): incidentally, the invention makes it possible to considerably limit the thickness of the intermediate deposit, or even to completely eliminate it, which significantly simplifies and shortens the process of manufacturing the reflector.
  • This very thin sub-layer can in particular serve as a barrier layer to corrosion.
  • a varnish deposition step is removed (reworking and then drying / crosslinking of the varnish).
  • varnishes were generally deposited in thicknesses of the order of one micrometer, not of the order of one nanometer (for example between 20 and 50 microns), which considerably modified the roughness with respect to the surface resulting from molding. by injection.
  • the addition of fibers is not another step, since the usual molding process of the polymer structures, of the injection type, is quite similar to a polymer matrix alone or to a mixture matrix + fibers.
  • this fibrous material can also have a positive impact on the mechanical properties of the reflector, also fulfilling the role of reinforcement material. It is thus possible to design thinner reflectors, even lighter, at the same level of mechanical performance, or, when high mechanical stresses exist, to recommend polymer reflectors where, usually, all-metal reflectors would be recommended.
  • the level of surface roughness of the polymer structure is adjusted (for example by modulating the characteristics of the fibers, in particular their rate in the structure) so that its surface state has a roughness such as its arithmetic mean difference.
  • Ra is at least 0.1 micrometer, especially at least 0.2 micrometer.
  • the surface state of the polymer-based structure has a roughness such that its arithmetic average of the local surface slopes Sda is at least 10 mradians, especially at least 15 mradians.
  • the surface state of the reflector measured on the reflective coating of the reflector has a roughness such that its arithmetical average deviation Ra is at least 0.1 micrometer, especially at least 0.2 micrometer and / or its arithmetic mean local slopes of surface Sda is at least 10 mradians, in particular at least 15 mradians.
  • the fibers are of essentially mineral nature, and are in particular of glass. It is also possible to use fibers made of ceramic material, carbon fibers.
  • Fibers of the reinforcing fiber type which are also used for the mechanical reinforcement of polymers in other fields of industry, are preferred.
  • This type of fiber generally consists of multitudes of unitary filaments, whose cohesion before introduction into the polymer is ensured by a suitable size.
  • the sizing is also studied to be chemically compatible with the polymer to be reinforced, and to promote the adhesion and dispersion of the fibers in the matrix.
  • the choice of the wick or wire, the choice of the cutting length or the length or diameter of the unit filaments or the fiber content with respect to the polymer are the parameters that can be adjusted according to the desired results.
  • the strands or wicks can be cut to a length of between 3 and 12 mm, in particular between 4 and 10 mm, more particularly around 6 mm. It should be noted that this is the initial length of the fibers when they are introduced into the polymer matrix (s), but that it can change (decrease) during the process until the end of the process. molding operation.
  • the threads or strands are based on single filaments with a diameter of between 8 and 30 microns, especially between 15 and 30 microns.
  • the structure based on polymer (s) has a fiber content of at least 5% by weight, especially at least 15%, preferably between 20 and 40% by weight. It has indeed been observed, all other things being equal, that there were preferred ranges of levels, below which the improvement of the optical properties of the reflector was not noticeable, and beyond which the effect was to stagnate or even to decrease: the light absorption of the surface then becomes predominant. On the other hand, up to a certain maximum threshold, it is possible, by modulating the fiber content, to modulate the angular distribution of the rays reflected by the reflector.
  • the reflector is associated with a standard halogen lamp type light source
  • a small angular distribution that is to say a cone of distribution of the angles reflected by a surface unit.
  • reflective given relatively narrow, since the total flux emitted by this type of lamp is lower than that emitted by an equivalent lamp Xenon type.
  • a xenon lamp which emits a greater luminous flux
  • the structure based on polymer (s) also comprises fillers, in particular lamellar type talc or mica, or granular type carbonates. Their presence can reduce the cost of raw materials of the structure, or facilitate the molding operations. Finally, it can also favorably influence the mechanical properties of the structure. But unlike the elongated fibers, they do not significantly change the surface roughness.
  • the reflector structure is advantageously based on thermosetting polymer (s) or thermoplastic (s), especially chosen from polysulfones, polyethersulfones, polyesters, polyetherimides and phenylene polysulfides.
  • the presence of fibers in the polymer of the reflector increases the mechanical properties of the reflector, which makes possible / facilitates the integration to said reflector of accessory elements, including mechanical fasteners, the lamp holder type, or shutter elements of the occulting type, mobile or fixed cover.
  • the invention also relates to a method of manufacturing a reflector for equipping a lighting or signaling device for a motor vehicle and comprising a structure based on polymer (s) covered at least partly with a reflective coating , such that said structure is manufactured by molding, of the injection type, of a mixture containing one or more polymers, fibers of the glass fiber type and optionally fillers.
  • the invention also relates to any lighting or signaling device for a motor vehicle, comprising at least one reflector as described above.
  • the invention also relates to any vehicle equipped with such a device.
  • modules intended to be integrated in motor vehicle headlights, comprise a light source 1, for example a xenon lamp or a halogen lamp.
  • Xenon lamps offer the advantage of emitting a higher luminous flux than halogen lamps, and of having in the usual conditions of use a longer service life and a lower power consumption.
  • the modules also comprise a reflector 2, a lens 3, carried by an intermediate part 4.
  • a moving cover 5 is provided: in the high position, it makes it possible, in a known manner, to obtain the beam at cutoff wanted.
  • it is retracted, for example by a tilting movement about a horizontal axis YY perpendicular to the optical axis XX as represented by the arrow of the figure 1a it no longer obstructs the light, and we then obtain a road-type beam.
  • the reflector especially in this configuration, does not waste more flux, so that it is as little absorbent in the visible as possible.
  • the rays are reflected by the reflector 2 with a much smaller angular amplitude (practically zero) than in the example No. 2 according to the invention shown in FIG. figure 1b .
  • the invention thus makes it possible to obtain a reflector that is not very absorbent and capable of reflecting in a diffusing manner, the latter characteristic making it possible to guarantee a homogeneity of the beam emitted by the projector that is significantly improved. Concretely, this means, as detailed below, that we will have no, or less, more intense spots than others in the beam, and that we will have sharper contours of sharper, better.
  • a reflector 2 is used, manufactured in the following manner: a polymer, polyphenylsulfide (PPS) with mineral fillers, is molded by injection in a mass ratio of 40% polymer / 60% fillers. These fillers consist of talc, mica and carbonates.
  • the molding process is known per se.
  • a very thin layer based on polysiloxane hexamethyldisiloxane
  • This layer has the particular function of chemical barrier, without inducing significant change in the surface condition of the underlying polymer.
  • an aluminum coating of a thickness of about 50 to 100 nm by a known vacuum evaporation metallization method or by sputtering.
  • the comparative example is reproduced, but by adding a third component in the polymer matrix + fillers before injection: Add reinforcing glass fibers in the form of wires consisting of unit filaments of about 15 micrometers in diameter and cut to a length of about 6 mm. The sizing of the fibers is compatible with the PPS. The weight ratio polymer / fillers / glass thread is 40/30/30.
  • the surface condition of the two reflectors before and after aluminization was then studied and the homogeneity of the optical beam obtained with each of the two modules was estimated.
  • the figures 3a (Example No. 1) and 3b (Example No. 2) also show the isolux obtained with each of the optical modules, using a halogen-type lamp 1 model H7, at a distance of about 15 m.
  • An optician sees very quickly, in view of these isolux, that the module according to Example 1 is less good in terms of homogeneity of the beam than the module according to Example 2, in all respects identical to the previous except for the presence of reinforcement fibers in the reflector: the isolux, especially the closest to the maximum intensity point, are less clear contour with the comparative example without fiberglass.
  • the inventors have thus discovered that adding a fibrous material in the polymer of the reflector substantially modifies its surface state: the values of Ra and Sda are multiplied by at least a factor of 3.
  • This adjustment of the surface state, this significant increase the surface roughness, by adding the glass fibers has a very advantageous and surprising impact: it has excellent optical results, the reflector, once aluminized, is very little absorbent and has a high specular reflection.
  • the modified reflector according to the invention passes without difficulty the durability tests usually practiced in the automotive field, as a standard reflector in solid aluminum or the reflector according to example 1.
  • the reflectors according to the invention are considerably more mechanically robust than the standard polymeric reflectors, with or without an intermediate varnish. This means that one can then afford, with the invention, to reduce the thickness of the reflectors and / or to mold in one piece the actual reflector and ancillary elements of the type of mechanical fixing means.
  • the invention has thus made it possible to improve the mechanical and optical properties of the reflector, with a simpler manufacturing method, since it is possible to eliminate the intermediate lacquer layer without disadvantages, or at least to significantly reduce the thickness thereof. It should also be noted that the invention can likewise be applied to reflectors based on thermosetting polymers, and not only thermoplastics. It also applies to any lighting or signaling module, and is therefore not limited to an application to elliptical modules.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)
  • Optical Elements Other Than Lenses (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Claims (15)

  1. Reflektor (2), der zur Ausrüstung einer Beleuchtungs- oder Signalgebungsvorrichtung für Kraftfahrzeuge bestimmt ist und eine Struktur auf Polymerbasis aufweist, die wenigstens zum Teil mit einer reflektierenden Beschichtung überzogen ist, wobei die Struktur auch Fasern umfasst,
    dadurch gekennzeichnet, dass die auf der reflektierenden Beschichtung des Reflektors gemessene Oberflächenbeschaffenheit des Reflektors eine solche Rauheit aufweist, dass deren durchschnittliche arithmetische Abweichung Ra wenigstens 0,1 Mikrometer beträgt und/oder deren arithmetisches Mittel der lokalen Oberflächenneigungen Sda wenigstens 10 Milliradiant beträgt.
  2. Reflektor (2) nach Anspruch 1,
    dadurch gekennzeichnet, dass die Struktur von der reflektierenden Beschichtung unmittelbar oder mittels einer oder mehrerer Schichten mit einer Gesamtdicke von höchstens 50 nm, insbesondere von höchstens 10 nm überzogen ist.
  3. Reflektor (2) nach Anspruch 1 oder Anspruch 2,
    dadurch gekennzeichnet, dass die Oberflächenbeschaffenheit der Struktur auf Polymerbasis eine solche Rauheit aufweist, dass deren durchschnittliche arithmetische Abweichung Ra wenigstens 0,1 Mikrometer, insbesondere wenigstens 0,2 Mikrometer beträgt.
  4. Reflektor nach einem der vorhergehenden Ansprüche,
    dadurch gekennzeichnet, dass die Oberflächenbeschaffenheit der Struktur auf Polymerbasis eine solche Rauheit aufweist, dass deren arithmetisches Mittel der lokalen Oberflächenneigungen wenigstens 10 Milliradiant, insbesondere wenigstens 15 Milliradiant beträgt.
  5. Reflektor nach einem der vorhergehenden Ansprüche,
    dadurch gekennzeichnet, dass die auf der reflektierenden Beschichtung des Reflektors gemessene Oberflächenbeschaffenheit des Reflektors eine solche Rauheit aufweist, dass deren arithmetische Abweichung Ra mindestens wenigstens 0,2 Mikrometer beträgt und/oder deren arithmetisches Mittel der lokalen Oberflächenneigungen Sda wenigstens 15 Milliradiant beträgt.
  6. Reflektor nach einem der vorhergehenden Ansprüche,
    dadurch gekennzeichnet, dass die Fasern anorganischer Natur sind, insbesondere in Form von Glasfasern.
  7. Reflektor nach einem der vorhergehenden Ansprüche,
    dadurch gekennzeichnet, dass die Fasern Verstärkungsfasern sind, die insbesondere in die Polymergrundmasse in Form von Strängen oder Fäden eingebracht sind, welche insbesondere zugeschnitten sind und ihrerseits aus Einzelfäden bestehen.
  8. Reflektor nach einem der vorhergehenden Ansprüche,
    dadurch gekennzeichnet, dass die Fäden oder Stränge auf eine Länge von 3 bis 12 mm, insbesondere von 4 bis 10 mm zugeschnitten sind.
  9. Reflektor nach Anspruch 7 oder Anspruch 8,
    dadurch gekennzeichnet, dass die Fäden oder Stränge aus Einzelfäden mit einem Durchmesser von 8 bis 30 Mikrometer, insbesondere von 15 bis 30 Mikrometer bestehen.
  10. Reflektor nach einem der vorhergehenden Ansprüche,
    dadurch gekennzeichnet, dass die Struktur auf Polymerbasis auch Füllstoffe aufweist, insbesondere schuppenförmige vom Typ Talk oder Glimmer oder körnige vom Typ Karbonat.
  11. Reflektor nach einem der vorhergehenden Ansprüche,
    dadurch gekennzeichnet, dass die Struktur auf Polymerbasis einen Fasergehalt von wenigstens 5 Gew.-%, insbesondere von wenigstens 15 Gew.-%, vorzugsweise zwischen 20 und 40 Gew.-% aufweist.
  12. Reflektor nach einem der vorhergehenden Ansprüche,
    dadurch gekennzeichnet, dass die Struktur aus thermoplastischen Polymeren besteht, insbesondere Polysulfonen, Polyethersulfonen, Polyestern, Polyetherimiden, Polyphenylensulfiden.
  13. Reflektor nach einem der vorhergehenden Ansprüche,
    dadurch gekennzeichnet, dass in dem Reflektor Elemente zur mechanischen Befestigung integriert sind, insbesondere ein Lampenträger oder Abdeckelemente vom Typ Abschatter, beweglicher oder feststehender Blende.
  14. Verfahren zur Herstellung eines Reflektors, der zur Ausrüstung einer Beleuchtungs- oder Signalgebungsvorrichtung für Kraftfahrzeuge bestimmt ist und eine Struktur auf Polymerbasis aufweist, die wenigstens zum Teil mit einer reflektierenden Beschichtung überzogen ist,
    dadurch gekennzeichnet, dass die Struktur durch Gießen vom Typ Spritzgießen einer Mischung erzeugt wird, die ein oder mehrere Polymere, Fasern vom Typ Glasfasern und gegebenenfalls Füllstoffe enthält, damit die auf der reflektierenden Beschichtung des Reflektors gemessene Oberflächenbeschaffenheit eine solche Rauheit aufweist, dass deren durchschnittliche arithmetische Abweichung Ra wenigstens 0,1 Mikrometer und/oder deren arithmetisches Mittel der lokalen Oberflächenneigung Sda wenigstens 10 Milliradiant beträgt.
  15. Beleuchtungs- oder Signalgebungsvorrichtung für Kraftfahrzeuge,
    dadurch gekennzeichnet, dass sie wenigstens einen Reflektor nach einem der Ansprüche 1 bis 13 umfasst.
EP05291920A 2004-09-21 2005-09-16 Beleuchtungs- und/oder Signaleinrichtung Reflektor für Fahrzeugen Not-in-force EP1637798B1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
FR0409982A FR2875579B1 (fr) 2004-09-21 2004-09-21 Reflecteur de dispositif d'eclairage et/ou de signalisation pour vehicule automobile

Publications (2)

Publication Number Publication Date
EP1637798A1 EP1637798A1 (de) 2006-03-22
EP1637798B1 true EP1637798B1 (de) 2009-01-21

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EP05291920A Not-in-force EP1637798B1 (de) 2004-09-21 2005-09-16 Beleuchtungs- und/oder Signaleinrichtung Reflektor für Fahrzeugen

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US (1) US20060067623A1 (de)
EP (1) EP1637798B1 (de)
JP (1) JP2006164949A (de)
AT (1) ATE421663T1 (de)
DE (1) DE602005012468D1 (de)
FR (1) FR2875579B1 (de)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5075705B2 (ja) * 2008-03-26 2012-11-21 パナソニック株式会社 照明器具
US10544499B1 (en) 2018-08-13 2020-01-28 Valeo North America, Inc. Reflector for vehicle lighting
FR3137154B1 (fr) * 2022-06-22 2024-07-05 Valeo Vision Module d’éclairage automobile a coupure avec réflecteur à surface partiellement grainée

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0630955B1 (de) * 1993-06-25 1999-09-01 Sumitomo Chemical Company Limited Flüssigkristallpolyesterzusammensetzung und Lampenreflektoren
JPH07122106A (ja) * 1993-10-28 1995-05-12 Toray Ind Inc 鮮映性の優れたランプリフレクター用樹脂組成物
JP3174271B2 (ja) * 1995-07-27 2001-06-11 株式会社小糸製作所 ランプ反射鏡用成形組成物、それを用いたランプ反射鏡の製造方法及びランプ反射鏡
US5865530A (en) * 1996-02-15 1999-02-02 Valeo Sylvania Filled resin lamp reflector with no base coat and method of making
JPH1096806A (ja) * 1996-09-20 1998-04-14 Dainippon Printing Co Ltd ディスプレイ用反射材
JPH11238401A (ja) * 1998-02-20 1999-08-31 Nippon Zeon Co Ltd 車両用灯具のエクステンションリフレクタ
KR100540770B1 (ko) * 1998-02-20 2006-01-10 니폰제온 가부시키가이샤 등기구
CN1328746C (zh) * 2001-08-31 2007-07-25 库尔选项公司 导热车灯反射镜
US20050085589A1 (en) * 2003-10-20 2005-04-21 General Electric Company Modified weatherable polyester molding composition

Also Published As

Publication number Publication date
DE602005012468D1 (de) 2009-03-12
FR2875579A1 (fr) 2006-03-24
EP1637798A1 (de) 2006-03-22
ATE421663T1 (de) 2009-02-15
JP2006164949A (ja) 2006-06-22
US20060067623A1 (en) 2006-03-30
FR2875579B1 (fr) 2012-12-14

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