EP1813860B1 - Occultation element for the reflector of a projector and method for mounting such an element - Google Patents

Description

The subject of the present invention is a concealment element, usually called a concealer, intended to be positioned from the front within a reflector-type element in an optical module fitted to a lighting and / or automobile signaling device. projector type, and a method of mounting said occlusion member within such a device.

The object of the invention is essentially to propose a solution for making it possible, within a reflector of a projector optical module, to use a concealment element that is independent of the installation of the light source of the projector. projector device considered, while improving - by saving time, by reducing the risk of damaging sensitive areas of the reflector, and by a decrease in the probability of making a mounting error - the mounting process. In addition, the object of the invention is achieved by making possible an automation of the mounting process of the projector device, in particular by inserting a keying element at the occultation element to be placed within each reflector; each occulting element is thus associated with a single type of reflector on which it must be mounted.

• des feux de position, d'intensité et de portée faible ;
• des feux de croisement, ou codes, d'intensité plus forte et de portée sur la route avoisinant 70 mètres ;
• des feux de route longue portée, et des feux de complément de type longue portée, dont la zone de vision sur la route avoisine 200 mètres ;
• des projecteurs perfectionnés, dits bimodes, qui cumulent les fonctions de feux de croisement et de feu de route en incorporant un cache amovible ;
• des feux anti-brouillard ;
• des feux de signalisation....

The field of the invention is, in general, that of motor vehicle headlights. In this field, we know different types of projectors, among which we find essentially:

• position, intensity and low range lights;
• low beam, or codes, of greater intensity and range on the road close to 70 meters;
• long-range headlamps, and long-range supplement lights, whose vision zone on the road is approximately 200 meters;
• advanced projectors, called dual mode, which combine the functions of low beam and high beam by incorporating a removable cover;
• fog lights;
• traffic lights ....

In the field of projectors, there are two main families which correspond to two distinct arrangements of elements within the projectors:

The first family is that of so-called parabolic projectors. In this type of projectors, a light beam is generated by a small light source disposed in a reflector, or mirror. The projection on the road of the light rays reflected by a suitable reflector makes it possible to directly obtain a light beam obeying the various constraints imposed by the standards. Such a projector device may optionally be supplemented by an ice-type exit surface, which may be provided for example with ridges for modifying the light beam, for example by spreading it in width. The second family is that of so-called elliptical projectors. In this family of projectors, a spot of light concentration is generated by a light source disposed in a reflector. The spot of light concentration is then projected onto the road by a convergent lens, for example a plano-convex lens. The present invention applies to the two families just mentioned.

In these different types of projectors, it may be necessary to block some of the light rays emitted by the light source, in particular to remove certain rays said uprights, which are poorly controlled by the optical surfaces. For this purpose, it is expected the use of occulting elements, which are in the form of an additional piece forming a partially open envelope around the light source. Their presence makes it possible to rectify certain problems of appearance of the luminous flux produced.

In general, the invention can be implemented for all optical modules of projectors whose light source emits light signals, at least part of which must be obscured. The document US 6513956 shows such an optical module.

In the past, essentially optical modules were used whose shield was crimped onto a crown screwed onto a reflector, made for example from a thermosetting material; the crown was also involved in maintaining the light source within the projector device considered. Due to their attachment on a common ring, the concealer and the light source were positioned within the reflector during the same insertion operation, which, for particular reasons mounting, including wiring of the light source, was performed by the rear of the reflector, that is to say by bringing the assembly supported by the crown of the non-reflective side of the reflector, and passing the light source associated with the occluder through an insertion cavity provided at the bottom of the reflector until the ring arrives in its fixing position.

As shown in Figures 1-A and 1-B a reflector 100 receiving, in accordance with this introduction principle, a light source 101 and a concealer 102 composed essentially of a holding foot 103 and an occulting part 104 intended to partially surround the light source 101, had to have a cavity of introduction 105, having in particular a generally circular portion 106 extended downwardly by a generally rectangular portion 107 necessary to pass the holding foot 103. The presence of the rectangular portion 107, cumulative to the importance of the diameter of the circular portion 106 - importance needed to pass the blackout, whose dimensions in width were necessarily larger than those of the light source - created a large introduction cavity, thus depriving the reflector of a significant amount of reflective surface this loss inevitably resulted in a significant loss of flu x luminous produced by the projector device.

In the state of the art, in order to solve the problems just mentioned, solutions have been proposed for reducing the size of the introduction cavities in the reflectors. In particular, it has been proposed, as illustrated in Figures 2-A and 2-B , no longer use a common fastening element, as was the case with the crown, for a light source 200 and a concealer 201. Thus, the light source 200 continues to be introduced from the rear within a reflector 202, through a first insertion cavity 203, but the occluder can now be placed from the front within the reflector 202. By placement - or introduction - from the front within the reflector, denotes the fact that the placed element - or introduced - is positioned within the reflector being directly presented opposite the reflective portion of the reflector.

The occulter 201 is thus no longer obliged to pass through the first cavity 203, and can be directly maintained by introducing, at the front, at least a portion of a retaining tab 204 of an occulting portion 205 in a second insertion cavity 206, preferentially disposed below the first insertion cavity 203, while being distinct from this first cavity. A reflective surface gain is thus achieved, the dimensions of the first cavity 203 being smaller than those of the circular portion 106 of the insertion cavity 105 shown in FIGS. Figures 1-A and 1-B since the occulting portion 205 no longer has to cross. Furthermore, the rectangular portion 107 is replaced by the second insertion cavity 206, of smaller area and now makes possible the presence of an additional reflective zone 207 present between the first cavity 203 and the second cavity 206.

A problem arises however. By positioning the concealer by the front of the reflector, the risks of coming into contact with the reflective optical surfaces of said reflector are high, thus leading to probable damage to these surfaces or at least the appearance of imprints on these surfaces. surfaces. Such phenomena are detrimental to the quality of the light beam produced. Such a problem was not encountered with past solutions consisting of an introduction of the concealer by the rear of the reflector.

The object of the invention proposes a solution to the problem just described. In general, the invention proposes an automation of the operation of setting up by the front of a concealer within a projector device reflector.

By automating this operation, it ensures the accuracy of the movements of the occulting during its positioning within the reflector, the risk of damage to the optical surfaces of the reflector is thus canceled. In addition, to adapt to this automation that excludes all human control, to ensure that a shield is set up in the reflector to which it is actually intended, it is intended, in the invention, to place marks of keying on the occulteur to position. The keying performed is an inter-product keying, making it possible to check, by means of an automated control process, the match between an occluder and the reflector in which it is about to be mounted.

The invention therefore relates to an optical module according to claim 1 and its mounting method.

Advantageously, this or these polarization marks is / are arranged (s) in such a way that the rays emitted by the light source do not reach them or substantially not (frontally or obliquely), whether in direct light or after one or more reflections on the reflector: these foolproofing marks do not disturb / substantially modify the light beam emitted by the module.

A preferred arrangement for these marks to play substantially no optical role in the light beam emitted by the module is that they are arranged along an axis parallel to the optical axis of the optical module. They may be in a plane containing the optical axis of said module, in particular a substantially vertical plane in the optical module mounting position,

These marks are preferably located at the level of the holding foot of the occluder, whose support plane passes through a plane containing the optical axis of the module (including vertical plane).

• au moins une partie des trous de contrôle est ménagée dans un plan support de la patte de maintien ;
• le plan support du pied de maintien est contenu dans un plan contenant l'axe optique du dispositif projecteur, notamment un plan substantiellement vertical quand le dispositif est en position de montage dans un véhicule ;
• la marque de détrompage comporte un positionnement relatif des trous de contrôle ;
• la marque de détrompage comporte un nombre de trous de contrôle ;
• le pied de maintien comporte au moins une cavité produite par une opération de solidarisation de deux demi-flancs formant le pied de maintien, ladite cavité étant assimilée à un trou de contrôle ;
• la marque de détrompage diffère selon que l'élément d'occultation est destiné à un dispositif projecteur gauche ou à un dispositif projecteur droit.

The occulting element according to the invention may also have, in addition to the characteristics mentioned above, one or more of the following secondary characteristics:

• at least a portion of the control holes is formed in a support plane of the holding tab;
• the support plane of the holding leg is contained in a plane containing the optical axis of the projector device, in particular a substantially vertical plane when the device is in mounting position in a vehicle;
• the foolproof mark comprises a relative positioning of the control holes;
• the foolproof mark has a number of holes control;
• the holding foot comprises at least one cavity produced by a securing operation of two half-flanks forming the holding foot, said cavity being assimilated to a control hole;
• the foolproofing mark differs according to whether the obscuration element is intended for a left projector device or a right projector device.

In the sense of the invention, the "holes" of control can be of very varied shapes and designs. These holes are preferably through. They can also be blind, or, more precisely, be in the form of recesses of appropriate depth depending on the detection means used, as will be detailed below. They can be of round section, oval or any other geometric form.

Another object of the invention is a method of assembly according to claim 11.

• l'opération de détrompage comporte les différentes étapes suivantes :
• les directions d'émission des faisceaux laser sont sensiblement parallèles ;
• plusieurs éléments d'occultation sont simultanément montés sur la chaîne de montage et soumis aux faisceaux laser sur la chaîne de montage.

The method according to the invention may also have, in addition to the main characteristics mentioned in the preceding paragraph, one or more of the following secondary characteristics:

• the keying operation comprises the following steps:
• the emission directions of the laser beams are substantially parallel;
• several concealment elements are simultaneously mounted on the assembly line and subjected to laser beams on the assembly line.

For the polarization operation, alternatives to a laser beam detection are quite possible: any other means for detecting the polarization holes can be used other than the laser, and in particular using mechanical systems, for example using needles.

The invention and its various applications will be better understood by reading the following description and examining the figures that accompany it.

• aux figures 1-A et 1-B, déjà décrites, une représentation schématique d'une ancienne solution de montage d'un élément d'occultation au sein d'un réflecteur;
• aux figures 2-A et 2-B, également déjà décrites, une représentation schématique d'une solution utilisée dans l'état de la technique pour le montage d'un élément d'occultation au sein d'un réflecteur;
• à la figure 3, un exemple de réalisation d'un élément d'occultation selon l'invention ;
• à la figure 4, une représentation schématique de mise en place d'un élément d'occultation selon l'invention au sein d'un réflecteur ;
• à la figure 5, une représentation détaillée d'un exemple de mécanisme de blocage de l'élément d'occultation sur le réflecteur selon l'invention;
• à la figure 6, un exemple de mise en oeuvre du procédé selon l'invention;
• à la figure 7, une représentation plus détaillée d'un élément intervenant dans l'exemple de mise en oeuvre représenté à la figure 6.

These are presented only as an indication and in no way limitative of the invention. The figures show:

• to the Figures 1-A and 1-B , already described, a schematic representation of an old solution for mounting a concealment element within a reflector;
• to the Figures 2-A and 2-B , also already described, a schematic representation of a solution used in the state of the art for mounting a concealment element within a reflector;
• to the figure 3 an embodiment of a concealment element according to the invention;
• to the figure 4 , a schematic representation of implementation of a concealment element according to the invention within a reflector;
• to the figure 5 a detailed representation of an exemplary locking mechanism of the occulting element on the reflector according to the invention;
• to the figure 6 an example of implementation of the method according to the invention;
• to the figure 7 , a more detailed representation of an element involved in the embodiment shown in FIG. figure 6 .

The elements appearing in different figures retain, unless otherwise specified, the same references. Moreover, the various terms for designating relative positions of elements, or directions of displacement of elements, are used by considering a usual position of these elements when they are placed in a projector device mounted on a vehicle.

The figure 3 shows an example of occulting element 300 according to the invention. The figure 4 shows the occulteur 300 ready to be placed within a reflector 400.

The occluder 300 is made of rolled sheet metal rolled, for example aluminum or aluminum. It consists of two main parts: a tab, or foot, holding 301 and an occulting portion 302. The holding leg 301 is obtained by bringing together, until a contact is made, a first half-flank 303 and a second half-flank 304 after rolling the occulting portion 302. The first half-flank 303 and the second half-flank 304 are joined by an otherwise known industrial process, for example by performing a stamping operation. Alternatively, as shown in Figure 2A , the fastening can be made by folding at least one tab. This joining is reflected inter alia by the appearance of cavities, a first cavity 314 and a second cavity 315 in the example shown, having on their periphery a slight bulge of material, obtained for example by a punching operation, which contributes to the relative maintenance of the two half-flanks.

• une section rectangulaire 305 du pied de maintien 301 permet d'une part de rigidifier ledit pied de maintien, mais aussi, du fait de la faible épaisseur de cette section rectangulaire, d'obtenir une ombre projetée de plus petite taille, créée par une source lumineuse 401 sur une partie inférieure d'une surface réfléchissante 402 du réflecteur 400. La rigidité de la section rectangulaire est encore augmentée par la présence, sur chaque demi-flanc 303 et 304, d'un renflement 306 sous forme d'un renfoncement permettant d'augmenter la raideur du matériau localement. Ce renflement est optionnel, et peut donc être supprimé.
• un premier demi-cône 307 et un second demi-cône 308 constituant l'extrémité du pied de maintien 301 destinée à être introduite dans une cavité d'introduction 403 du réflecteur, équivalente à la cavité d'introduction 206 mentionnée précédemment. Les deux demi-cônes 307 et 308 ne sont pas solidarisés l'un à l'autre. Un espace 309 subsiste entre eux deux, ce qui leur confère une souplesse importante, souplesse avantageuse lorsqu'ils sont introduits dans la cavité 403. Par leur intermédiaire, le pied de maintien peut ainsi être contraint dans un logement 500 défini par la cavité 403.

The occluder 300 comprises first of all a number of structural characteristics which make it possible to improve its mechanical properties:

• a rectangular section 305 of the holding leg 301 makes it possible on the one hand to stiffen said support leg, but also, because of the small thickness of this rectangular section, to obtain a smaller projected shadow, created by a source 401 on a lower portion of a reflective surface 402 of the reflector 400. The rigidity of the rectangular section is further increased by the presence, on each half-flank 303 and 304, a bulge 306 in the form of a recess for increasing the stiffness of the material locally. This bulge is optional, and can be deleted.
• a first half-cone 307 and a second half-cone 308 constituting the end of the holding leg 301 intended to be introduced into an insertion cavity 403 of the reflector, equivalent to the insertion cavity 206 mentioned above. The two half-cones 307 and 308 are not secured to each other. A space 309 remains between them, which gives them great flexibility, advantageous flexibility when introduced into the cavity 403. Through them, the support foot can be constrained in a housing 500 defined by the cavity 403.

• dans un premier temps, dans un premier sens 407, correspondant au sens d'introduction, par la présence d'un premier flanc 310 et d'un deuxième flanc 311 marquant la fin de la section rectangulaire 305 du côté des demi-cônes 307 et 308, le premier flanc 310 et le deuxième flanc 311 présentant un léger écartement qui augmente la zone d'appui contre un rebord 406 de la cavité d'introduction 403 ;
• dans un second temps dans un deuxième sens, opposé au sens d'introduction, par le rabattement, visible à la figure 5, d'une première patte de fixation 312 et d'une deuxième patte de fixation 313 placée aux extrémités libres de chaque demi-cône 307 et 308. Ces pattes jouent donc le rôle de pattes d'arrêt en translation repliables.

The cavity 403 is of conical shape and comprises, in this example, a first rib 404 and a second rib 405 which allow on the one hand to guide in translation the insertion movement of the half-icons 307 and 308 in the cavity 403, and secondly to block in rotation the holding foot 301, and therefore the occulteur 300, once the two half-cones are introduced into the cavity 403. The translation stop during this introduction movement , is assured :

• in a first step, in a first direction 407, corresponding to the introduction direction, by the presence of a first sidewall 310 and a second sidewall 311 marking the end of the rectangular section 305 on the side of the half-cones 307 and 308, the first sidewall 310 and the second sidewall 311 having a slight spacing which increases the bearing area against a flange 406 of the insertion cavity 403;
• in a second time in a second direction, opposite to the sense of introduction, by folding, visible to the figure 5 , a first fixing lug 312 and a second fixing lug 313 placed at the free ends of each half-cone 307 and 308. These lugs therefore act as collapsible translational locking lugs.

Mounting the concealer in the reflector thus uses three mechanical means (independently or in combination with the control holes): the generally conical shape (308, 307) of the holding foot of the concealer associated with the complementary shape of the cavity ( 403) in the reflector for positioning longitudinal correctness of the occulter, the presence of at least one groove, in particular two opposite grooves, (404, 405) making it possible to correctly orient the foot of the occluder in the corresponding cavity of the reflector along an axis perpendicular to the preceding one, and the foldable translation stop tabs (312,313) of the holding foot of the concealer, ensuring the longitudinal locking of the foot of the occulter once in position.

In the invention, provision is made to automate the method of mounting the concealer 300 within the reflector 400. Thus, it is proposed, in an exemplary mounting method, to arrange each concealing element 300 in a support 600 which is automatically positioned opposite the reflector 400, and more precisely facing its reflective face 402. A relative translational movement, in the insertion direction 407, between the support piece 600 and the reflector 400 will then allow the introduction of the half cones 307 and 308 in the insertion cavity 403.

Human presence is no longer essential for this editing operation. If this absence has advantages in terms of handling accuracy and speed of assembly, a visual check to verify that the right occluder is placed on the right reflector is no longer achieved. Thus, in the invention, it is proposed to perform a control operation, also called keying operation, to determine a reference of the occulteur 300 and verify that the determined reference corresponds to the reflectors present on the assembly line.

It is proposed, in the example described, to have the keying marks at the retaining leg 301, said polarization marks here consisting of a set of coding holes 316 passing through the support leg 301 in the direction of its thickness. finer: the keying holes are formed in a support plane of the holding foot 301, said support plane being contained in a vertical plane containing the optical axis (defined as the axis corresponding to the direction of maximum amplitude of luminous flux) ) of the projector device in which the various elements described are mounted.

The number of coding holes 316 and / or their relative positioning defines a particular combination which makes it possible to determine a reference of the masker 300. By way of nonlimiting example, they can be 3 to 10, in particular 4 to 8, for example 5 in number. their diameter is variable, for example of the order of 1 to 4 mm in diameter, in particular about 2.5 mm. The occluder can be "coded" by adjusting the layout, number and size of keying holes 316 and 314.

From their position in figure 3 it can be seen that these holes 316, 314 are contained in a plane, in disassembly position, which contains the optical axis of the module: the rays of the source can not "pass" through the holes 316, 314, even partially, they do not therefore play no or almost no role in the light beam compared to a prior art shader with full support foot.

The reference of the occluder is associated bijectively with a specific cutting shape 317 of the occulting portion 302, and, still bijectively, with a reflector shape, a reflector shape determined essentially by the definition of the reflecting surface 402. Occultors intended to equip a right projector device and a left headlight device of the same motor vehicle may have different references, the reflectors present in these two projectors devices are not necessarily identical.

Also, in the invention, the support 600 has a shape such that, when the occluder 300 is placed in said support 600, the keying holes 316 are not hidden by any part of the support 600. In practice, one or more reflectors 400 of the same type are placed on a assembly line. As many occulters 300 as reflectors 400 are placed in the supports 600 which are themselves positioned opposite the reflectors, as described above. The different supports are aligned so that the coding holes 316 are also aligned in a direction perpendicular to the support plane of the retaining tabs 301.

In the invention, provision is then made to transmit a series of laser beams 601. The number of laser beams and their relative positioning defines a combination which is determined by considering a reference of the reflectors 400 arranged on the assembly line. The determined combination is such that the various laser beams of this combination are emitted by aiming at real keying holes, which correspond to the keying holes of a theoretical concealer actually intended to be mounted on the reflector 400.

The laser beams may for example be emitted by a first set of optical fibers, and recovered by a second set of optical fibers, arranged vis-à-vis the first set of optical fibers. Thus, a system for reading the foolproofing marks of the occulters 300 is formed: in the case where all of the laser beams emitted by the first set of optical fibers are recovered by the second set of optical fibers, then all the laser beams have actually passed through. a coding hole 316, and the concealer 300 then corresponds well to the expected theoretical concealer on the assembly line. The editing operation can then continue normally. In the opposite case, the editing operation is interrupted, and it is determined which are the unsuitable occultors for removing them from the assembly line. The "reading" of the keying holes can also be done mechanically.

Claims (12)

1. Optical module for a headlight, comprising a occultation element (300) placed in a reflector (400) of said optical module, the occultation element comprising a holding foot (301) and a occultation part (302) intended to at least partially surround a light source (401) of the headlight device, characterised in that the occultation element comprises at least one positive-location mark (316) for revealing a reference of said occultation element, the positive-location mark (316) comprises a plurality of check holes, the number of holes and/or the relative positioning thereof defining a particular combination determining said reference of said occultation element (300), the occultation part (302) of said element having a specific cutout designated by said reference.
2. Optical module according to the preceding claim, characterised in that the positive-location mark or marks (316) are disposed on an axis parallel to the optical axis of the module, or on a plane passing through the optical axis of the module.
3. Optical module according to one of the preceding claims, characterised in that at least some of the check holes/positive-location marks are provided in a surface supporting the holding lug.
4. Optical module according the preceding claim, characterised in that the surface supporting the holding foot is contained in a plane containing the optical axis of the optical module.
5. Optical module according to at least one of claims 2 to 3, characterised in that the positive-location mark comprises a relative positioning of the check holes (316).
6. Optical module according to at least one of claims 1 to 5, characterised in that the positive-location marks comprise a number of check holes (316).
7. Optical module according to at least one of claims 1 to 6, characterised in that the holding lug comprises at least one cavity (314; 315) produced by an operation of connecting together two half-flanks (303; 304) forming the holding lug.
8. Optical module according to at least one of the preceding claims, characterised in that the positive-location mark differs depending on whether the occultation element is intended for an optical module of a left headlight or a right headlight.
9. Optical module according to at least one of the preceding claims, characterised in that holding foot (301) is provided with means of relative orientation with respect to the cavity (304) for introduction of the reflector (400), in particular in the form of at least one groove (404, 405).
10. Optical module according to at least one of the preceding claims, characterised in that the holding foot (301) is provided with foldable translational-stop lugs (312, 313).
11. Method for mounting an optical module according to at least one of the preceding claims, with an occultation element in a reflector (400) for a headlight optical module, said method comprising the following various steps:

    - bringing the occultation element, from the front, into the reflector (400) to be equipped;

    - inserting a holding lug (301) for the occultation element in an insertion cavity (403) provided in the reflector;

    the assembly method being automated and comprising a supplementary step performing, prior to the step of inserting the holding lug in the insertion cavity, an operation of positive location of the occultation element in order to verify agreement of reference between the occultation element and the reflector to be equipped, characterised in that the positive-location operation comprises the following various steps:

    - placing at least one occultation element on an assembly line, each occultation element comprising at least one check hole (316);

    - emitting at least one laser beam (601), each laser beam being emitted in a direction aimed at a position corresponding to a theoretical check hole of an occultation element the reference of which agrees with that of the reflector to be equipped;

    - recovering the laser beams that have passed through the check holes of the occultation element placed on the assembly line;

    - verifying that the number of laser beams emitted is equal to the number of laser beams recovered; if so, proceeding with the assembly of the checked occultation element in the reflector to be equipped.
12. Method according to claim 11, characterised in that a plurality of occultation elements are simultaneously mounted on the assembly line and subjected to the laser beams on the assembly line.

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