EP1925876A1 - LED light source system - Google Patents

Abstract

The system (SYS) has LED-light sources (LIQ1, LIQ2, LIQ3) with a light emitting diode, where an auxiliary optic (VOP1-VOP3) is provided for each LED-light sources. LED-light sources are fixed on a common mounting unit (MON). Each auxiliary optics consists of two set of auxiliary optic units. One set of auxiliary optic units are fixed connected together via a carrier unit (TRA) and are fixable with the carrier unit at the mounting unit for the LED-light sources. The auxiliary optic units are arranged together with reduced distance.

Description

The invention relates to an LED light source system for an LED light unit of a motor vehicle, wherein the LED light source system comprises two or more LED light sources, and wherein each LED light source has at least one light emitting diode, and wherein further for each LED light source at least one Additional optics is provided, and further the LED light sources are mounted on a common mounting element, each attachment optics consists of a first intent optical element and a second intent optical element, and the respective first intent optical element with the associated LED light source is firmly connected, and the second intent optical elements on a support member are fixedly connected to each other and the second attachment optical elements with the support member to the mounting member for the LED light sources can be fastened and positioned with respect to the LED light sources.

Usually, an LED light source consists of one or more LEDs, which are arranged on an LED print of a circuit board. In front of the LEDs, a primary optics is arranged, by means of which the light emerging from the LEDs is collected and distributed accordingly. Multiple reflections in the primary optics also lead to a thorough mixing of the light (integration effect). From the primary optics, the light enters a secondary optic, using which the desired light distribution is achieved.

In order to obtain the necessary luminous intensities for a desired light image, it is often necessary that a plurality of such above-mentioned LED light sources be used to generate the light distribution.

One difficulty with using multiple such LED light sources is that they must be aligned very accurately with each other for a proper light image. This already makes the production of such LED light source systems as relatively complicated, since tolerances in the production of the individual components are taken into account.

Another problem occurs when one or more LED modules have to be replaced as a result of a defect of LEDs, as it is usually extremely expensive to position them again as accurately as possible. In addition, there is also the problem of so-called "diversity", since different primary functions are required for different lighting functions. If this diversity is inextricably linked with the LED module, a correspondingly expensive storage is necessary for service purposes.

With an aforementioned LED light source system, the problems mentioned in the production of such a light source system and in particular in the replacement of one or more LED modules can be defused.

Such LED light source systems mentioned above are for example from the US 4,733,335 A , of the US 2003/0123260 A1 or the EP 0 326 668 A2 known.

By subdividing the primary optics in two stages, of which the first stages or intent optical elements are respectively connected to the LED light sources and the second stages or second intent optical elements are connected to each other, a referencing of the individual LED light sources to each other in a simple manner the interconnected second intent optical elements take place. The exact alignment of the second stages to each other is given by the manufacturing process and does not have to be performed until the assembly of the LED light source system, whereby a much better referencing is ensured.

Through the connection of the second attachment optical elements with each other, the number of lighting components to be adjusted decreases significantly, so that the adjustment is much easier.

When replacing an LED light source, the positioning of the new LED light source is less delicate, since the actual referencing of the LED light sources to each other via the second intent optical elements. When replacing an LED light source, the light emission surface of the primary optics (attachment optics) does not change its position, since the second intent optical elements keep their position unchanged.

Tolerances in the production of the LED light sources or deviations in the dimensions of the new LED light sources from the frames originally used are then less problematic to a certain extent.

Under "support member" is basically an arbitrary element to understand, with which it is possible to arrange the attachment optical elements in mutually fixed positions.

A disadvantage of such known LED light source systems are the occurring light losses, and it is an object of the invention to minimize such light losses.

This object is achieved with an LED light source system mentioned in the introduction in that, according to the invention, first and second auxiliary optical elements are arranged with the smallest possible distance from each other. In this way, the light losses, in particular the geometric light losses can be kept as low as possible. Optimal is an approaching zero distance at which the intent optical elements abut each other, since in this case the geometric light losses also go to zero.

It is particularly advantageous if the light exit surfaces of the first attachment optical elements and the light entry surfaces of the second attachment optical elements are positioned directly opposite each other and arranged such that substantially the entire luminous flux via the light exit surface from the first intent optical element off and on the light entrance surface of the associated second intent optical element enter this.

The light exit surfaces and light entry surfaces are preferably parallel to each other.

Due to the special inventive design or arrangement of the surfaces to each other is due to the so-called "integration effect", i. as a result of the light mixing due to total internal reflection in the first intent optical element, almost no light when passing from the first to the second intent optical element. This integration also tolerances in the components can be compensated.

Basically, one has to differentiate between reflection losses and geometric losses in the light losses between the two surfaces of the optical attachment elements. Depending on the surface finish, the reflection losses per area are approximately 0.4% - 4%, in total about 0.8% - 8%. By taking appropriate measures, these losses can therefore be kept very low (below 1%).

The geometric losses are light that passes laterally after exiting the first intent optical element on the second intent optical element. These geometric losses depend on the distance of the surfaces of the two attachment optical elements and the concrete geometry of the attachment optical elements.

In order to keep the geometric losses low, it is expedient if the light exit surface of a first intent optical element is smaller than the light entrance surface of the associated second intent optical element.

In this context, it is particularly advantageous for the light exit surfaces and the associated light entry surfaces to be arranged relative to one another such that the normal projection of the light exit surface onto the assigned light entry surface lies completely within the light entry surface.

The fact that in this variant, the light entry surface of the second intent optical element overlaps the light exit surface of the first intent optical element on each side, geometric light losses can be completely prevented or at least minimized.

After such a small distance manufacturing technology is difficult to manufacture and also a positioning of the optical attachment elements first and second stage to each other more difficult, a small gap in the form of a gap between the first and second intent optical element is usually provided.

In order to reduce or completely eliminate the reflection losses in the presence of such a gap between the additional optical elements, it can further be provided that the gap between the light exit surface of the first intent optical element and the light entry surface of the second optical element with a filler which has the same refractive index as the two additional optical elements , is filled up.

Preferably, a transparent or light-conducting gel ("index gel") is used as the filler. The gel should have a similar or the same refractive index as the optical attachment and absorb as little light as possible.

In a particularly simple and accurate to implement. System, the second intent optical elements are integrally formed with the carrier element.

Furthermore, it is for a simple and cost-effective production advantageous if the second intent optical elements and / or the carrier element are formed of a translucent plastic. In addition, in this case, the system carrier - optical attachment elements only a small weight, and when using a transparent plastic, it is also possible to form the optical attachment elements integral with the carrier.

In principle, however, the support element may be formed separately from the second attachment optical elements and have receptacles or holding means for receiving or holding the attachment optics.

Furthermore, it can be provided in a system according to the invention that each LED light source in addition to the primary optics in the form of intent optics is associated with a secondary optics, and that the individual secondary optics are connected to each other via a separate secondary optics support element.

The secondary optics may typically be a lens or a reflector. In most cases, they are free-form lenses or reflectors. These lenses project the exit surface of the attachment optics into the far field and form the desired light distribution.

The connection of the individual secondary optics via a separate secondary optics carrier element in turn offers the advantages already mentioned above in connection with the carrier for the second intent optical elements.

Furthermore, it may be advantageous if the secondary optics are formed integrally with the secondary optics carrier element.

It may also be favorable if the secondary optics and / or the secondary optics carrier element are formed from a translucent plastic.

Finally, it can also be advantageous if the secondary optics carrier element is formed separately from the secondary optics and has receptacles or holding means for receiving or holding the secondary optics.

The advantages of these embodiments of the secondary optics carrier element have already been discussed in connection with the carrier for the second intent optical elements.

For exact positioning of the second attachment optical elements with respect to the LED prints with the first intent optical elements fastening means for fastening and positioning of the carrier element are provided on the mounting member.

The carrier is referenced, for example by pins on the mounting element and then screwed / glued to this.

Furthermore, it is expediently provided that secondary optics carrier element fastening means are provided for fastening and positioning the secondary optics carrier element on the mounting element or for fastening and positioning on the carrier element for the second intent optical elements.

The mounting element serves as a common mechanical referencing for the support element and secondary optics support element, which is why a positioning of the secondary optics support element is possible both on the mounting element and on the support for the optical attachment elements. With regard to the tolerances, it is generally better to attach and position the secondary optics carrier element on the mounting element, since then the secondary optics carrier element can be positioned as accurately as possible relative to the carrier.

However, it can also be provided that each LED light source is assigned secondary optics in addition to the primary optics in the form of the intent optics, and that the individual secondary optics and the second intent optics are connected to one another via a common carrier. In this way, only one component, namely to refer to the common carrier.

The wearer may again assume different embodiments as discussed above in connection with the other supports discussed.

Due to the small tolerances that occur, it could also be advantageous to design the second additional optical elements and the secondary optics in the form of lenses in one piece.

To take special photographs, e.g. To be able to achieve a low-beam distribution, one or more LED light sources can be assigned at least one aperture each.

In a particularly advantageous embodiment, the diaphragms are each arranged directly on the light exit surface of the second intent optical element, e.g. in the form of a coating of the light exit surface. This variant has the advantage that a positioning of the aperture when assembling the light unit is not necessary, however, the production of the optical attachment elements is a little more complex.

In another embodiment, the panels are connected to one another via a screen carrier and arranged at a distance from the light exit surfaces. The shade support may again be referenced relative to the mounting element, i. be attached there.

However, it is also possible to refer to the prefabricated optical element carrier, or the lenses can also be held the same on this carrier or on another, for example, the abovementioned common carrier.

This embodiment has the advantage that, if it is provided that the panels are at least in one direction, preferably substantially parallel to the mounting element, slidably mounted or pivotable about at least one axis, this can be done simply by movement of only one part, if namely, the diaphragm support is at least in one direction, preferably substantially parallel to the mounting member, slidably mounted or pivotable about at least one axis. In this way, only the movement of a component, namely the diaphragm support is necessary, and not the movement of several individual diaphragms, and it is e.g. a headlamp leveling by shifting the aperture or the realization of another extended light function, in which the light-dark line must be adjusted in height possible.

Fig. 1

eine perspektivische Darstellung eines erfindungsgemäßen Systems,

Fig. 2

eine Seitenansicht des Systems aus Figur 1,

Fig. 3

eine Detaildarstellung einer LED-Lichteinheit,

Fig.4

eine weitere Ansicht der LED-Lichteinheit aus Figur 3, und

Fig. 5

einen Schnitt durch die LED-Lichteinheit aus Figur 3 bzw. 4.

In the following the invention is explained in more detail with reference to the drawing. In this shows

Fig. 1

a perspective view of a system according to the invention,

Fig. 2

a side view of the system of Figure 1,

Fig. 3

a detailed representation of an LED light unit,

Figure 4

another view of the LED light unit of Figure 3, and

Fig. 5

a section through the LED light unit of Figure 3 and 4, respectively.

FIGS. 1 and 2 show an LED light source system SYS for an LED light unit LEH of a motor vehicle, the LED light source system SYS in this embodiment comprising three LED light sources LIQ1, LIQ2, LIQ3. Each LED light source LIQ1, LIQ2, LIQ3 has at least one light emitting diode LED, as e.g. is indicated in Figure 5. The light emitting diode (s) LED is / are arranged on an LED print of a board LEP. The three LED light sources LIQ1, LIQ2, LIQ3 are mounted on a common mounting element MON.

In principle, a primary optics in the form of optical attachments VOP1, VOP2, VOP3 as part of the LED light sources LIQ1, LIQ2, LIQ3 is arranged in the light exit direction in front of the light emitting diodes LED, by means of which the light emerging from the light emitting diodes LED is collected and distributed accordingly. Multiple reflections in the primary optics also lead to a thorough mixing of the light (integration effect). From primary optics The light enters a secondary optics, using which the desired light distribution is achieved.

In the present invention, each front optics VOP1, VOP2, VOP3 consists of a first header optical element VOP11, VOP21, VOP31 and a second header optical element VOP12, VOP22, VOP32, the front optics VOP1, VOP2, VOP3 thus have a two-part structure. The respective first intent optical element VOP11, VOP21, VOP31 is fixedly connected to the associated LED light source LIQ1, LIQ2, LIQ3, and the second intent optical elements VOP12, VOP22, VOP32 are firmly connected to one another via a carrier element TRA.

Via the carrier element TRA, the second attachment optical elements VOP12, VOP22, VOP32 can be fastened to the mounting element MON for the LED light sources LIQ1, LIQ2, LIQ3 and can be positioned relative to the LED light sources LIQ1, LIQ2, LIQ3.

By dividing the primary optics VOP1, VOP2, VOP3 in two stages, of which the first stage or intent optical elements respectively connected to the LED light sources or part of the LED light sources and the second stages and second intent optical elements are connected to each other can a referencing of the individual LED light sources to each other in a simple manner via the interconnected second intent optical elements. The exact alignment of the second stages to each other is given by the manufacturing process and does not have to be performed until the assembly of the LED light source system, whereby a much better referencing is ensured.

Through the connection of the second attachment optical elements with each other, the number of lighting components to be adjusted decreases significantly, so that the adjustment is much easier.

The light exit surfaces LA1, LA2, LA3 of the first header optical elements VOP11, VOP21, VOP31 and the light entry surfaces LE1, LE2, LE3 of the second header optical elements VOP12, VOP22, VOP32 are positioned directly opposite each other and arranged such that substantially the entire luminous flux across the light exit surface LA1, LA2, LA3 from the first intent optical element VOP11, VOP21, VOP31 off and on the light entrance surface LE1, LE2, LE3 of the associated second additional optical element VOP12, VOP22, VOP32 enters this.

The light exit surfaces and light entry surfaces lie opposite each other in parallel.

Due to the special inventive design or arrangement of the surfaces to each other is due to the so-called "integration effect", i. as a result of the light mixing due to total internal reflection in the first intent optical element, almost no light when passing from the first to the second intent optical element. This integration also tolerances in the components can be compensated.

Basically, one has to differentiate between reflection losses and geometric losses in the light losses between the two surfaces of the optical attachment elements. Depending on the surface finish, the reflection losses per area are approximately 0.4% - 4%, in total about 0.8% - 8%. By taking appropriate measures, these losses can therefore be kept very low (below 1%).

The geometric losses are light that passes laterally after exiting the first intent optical element on the second intent optical element. These geometric losses depend on the distance of the surfaces of the two attachment optical elements and the concrete geometry of the attachment optical elements.

In order to be able to keep the geometric losses low, the light exit surface LA1, LA2, LA3 of a first intent optical element VOP11, VOP21, VOP31 is smaller than the light entrance surface LE1, LE2, LE3 of the associated second auxiliary optical element VOP12, VOP22, VOP32, and the associated light entry surfaces LE1, LE2, LE3 are arranged relative to one another in such a way that the normal projection of the light exit surface LA1, LA2, LA3 onto the assigned light entry surface LE1, LE2, LE3 lies completely within the light entry surface LE1, LE2, LE3.

As a result, geometric light losses can be completely prevented or at least minimized.

Another measure to minimize the geometric light losses is that the first and second intent optical element VOP11, VOP21, VOP31; VOP12, VOP22, VOP32 are arranged as close to each other as possible. Optimal is an approaching zero distance at which the intent optical elements abut each other, since in this case the geometric light losses also go to zero.

Since such a small distance is difficult to produce in terms of production and also makes positioning of the optical element elements of the first and second stages more difficult, a small gap in the form of a gap SPA between the first and second optical element is usually provided as shown, as shown particularly in FIGS 4 is clearly visible.

The second intent optical elements VOP12, VOP22, VOP32 are formed integrally with the carrier element TRA. The second intent optical elements VOP12, VOP22, VOP32 and the carrier element TRA are formed from a translucent plastic.

In addition, as already mentioned, each LED light source LIQ1, LIQ2, LIQ3 is assigned a secondary optics LEN1, LEN2, LEN3 in addition to the primary optics in the form of the front optics VOP1, VOP2, VOP3. The individual secondary optics LEN1, LEN2, LEN3 are connected to one another via their own secondary optics carrier element STR.

The secondary optics may typically be a lens or a reflector. In most cases, they are free-form lenses or reflectors. These lenses project the exit surface of the attachment optics into the far field and form the desired light distribution.

The connection of the individual secondary optics via a separate secondary optics carrier element in turn offers the advantages already mentioned above in connection with the carrier for the second intent optical elements.

In the illustration, the secondary optics LEN1, LEN2, LEN3 are integrally formed with the secondary optics support member STR.

For exact positioning of the second intent optical elements with respect to the LED prints with the first intent optical elements fastening means BEF1 are provided for fastening and positioning of the carrier element TRA to the mounting member MON.

The carrier is referenced for example by pins BEF1 to the mounting member MON and then screwed / glued to this.

Furthermore, it is expediently provided that secondary optics carrier element fastening means BEF2 are provided for fastening and positioning the secondary optics carrier element STR on the mounting element MON or for fastening and positioning on the carrier element TRA for the second intent optical elements. In the example shown, the fastening takes place by means of the fastening means BEF2 on the carrier TRA.

The fastening means BEF1, BEF2 are used for positioning and referencing the components to be referenced with respect to all three spatial axes. In the exact manner of positioning and fixing is not discussed here, since this can be done in a known manner.

To take special photographs, e.g. To be able to achieve a low-beam distribution, each LED light source LIQ1, LIQ2, LIQ3 is still a respective aperture BLE1, BLE2, BLE3 assigned.

In another embodiment, the diaphragms BLE1, BLE2, BLE3 are connected to one another via a diaphragm carrier BTR and are arranged at a distance from the light exit surfaces LA1 ', LA2', LA3 '. The shade carrier BTR may again be referenced relative to the mounting element, i. be attached there. In the example shown, the screen carrier BTR is attached to the attachment means BEF2 for the secondary optics.

However, it is also possible to refer to the prefabricated optical element carrier, or the lenses can also be attached to this carrier or to another, e.g. be held in the abovementioned common carrier.

If it is provided that the baffles BLE1, BLE2, BLE3 are at least in one direction, preferably substantially parallel to the mounting member MON, slidably mounted or pivotable about at least one axis, this is done simply by movement of only one part by the screen carrier BTR at least in one direction, preferably substantially parallel to the mounting member MON, slidably mounted or pivotable about at least one axis. In this way, only the movement of a component, namely the diaphragm support is necessary, and not the movement of several individual diaphragms, and it is e.g. a headlamp leveling by shifting the aperture or the realization of another extended light function, in which the light-dark line must be adjusted in height possible.

Claims (22)

LED light source system (SYS) for an LED light unit (LEH) of a motor vehicle, wherein the LED light source system (SYS) comprises two or more LED light sources (LIQ1, LIQ2, LIQ3), and wherein each LED light source (LIQ1, LIQ2 , LIQ3) has at least one light-emitting diode (LED), and wherein in each case at least one additional optical system (VOP1, VOP2, VOP3) is provided for each LED light source (LIQ1, LIQ2, LIQ3), and furthermore the LED light sources (LIQ1, LIQ2 , LIQ3) are mounted on a common mounting element (MON), each attachment optics (VOP1, VOP2, VOP3) consisting of a first intent optical element (VOP11, VOP21, VOP31) and a second intent optical element (VOP12, VOP22, VOP32), and the respectively first header optical element (VOP11, VOP21, VOP31) is fixedly connected to the associated LED light source (LIQ1, LIQ2, LIQ3), and the second header optical elements (VOP12, VOP22, VOP32) are fixedly connected to each other via a carrier element (TRA) and the second Additional optical elements (VOP1 2, VOP22, VOP32) with the carrier element (TRA) can be fastened to the mounting element (MON) for the LED light sources (LIQ1, LIQ2, LIQ3) and can be positioned relative to the LED light sources (LIQ1, LIQ2, LIQ3),
characterized in that
First and second intent optical element (VOP11, VOP21, VOP31, VOP12, VOP22, VOP32) are arranged as close to each other as possible. A system according to claim 1, characterized in that the light exit surfaces (LA1, LA2, LA3) of the first header optical elements (VOP11, VOP21, VOP31) and the light entry surfaces (LE1, LE2, LE3) of the second header optical elements (VOP12, VOP22, VOP32) are immediately adjacent to each other are positioned opposite one another and are arranged such that substantially the entire luminous flux via the light exit surface (LA1, LA2, LA3) from the first intent optical element (VOP11, VOP21, VOP31) off and on the light entry surface (LE1, LE2, LE3) of the associated second intent optical element (VOP12, VOP22, VOP32) enters this. A system according to claim 2, characterized in that the light exit surface (LA1, LA2, LA3) of a first intent optical element (VOP11, VOP21, VOP31) is smaller than the light entrance surface (LE1, LE2, LE3) of the associated second optical intent element (VOP12, VOP22, VOP32 ). System according to claim 3, characterized in that the light exit surfaces (LA1, LA2, LA3) and the associated light entry surfaces (LE1, LE2, LE3) are arranged to each other such that the normal projection of the light exit surface (LA1, LA2, LA3) on the associated light entry surface (LE1, LE2, LE3) lies completely within the light entry surface (LE1, LE2, LE3). System according to one of Claims 1 to 4, characterized in that the distance between the first and second intent optical elements (VOP11, VOP21, VOP31, VOP12, VOP22, VOP32) approaches zero. System according to claim 5, characterized in that the gap (SPA) between the light exit surface (LA1, LA2, LA3) of the first intent optical element (VOP11, VOP21, VOP31) and the light entry surface (LE1, LE2, LE3) of the second intent optical element (VOP12, VOP22, VOP32) with a filler which has the same refractive index as the two additional optical elements (VOP11, VOP21, VOP31, VOP12, VOP22, VOP32). System according to claim 6, characterized in that a transparent or light-conducting gel is used as filler. System according to one of claims 1 to 7, characterized in that the second intent optical elements (VOP12, VOP22, VOP32) are formed integrally with the carrier element (TRA). System according to one of claims 1 to 8, characterized in that the second attachment optical elements (VOP12, VOP22, VOP32) and / or the carrier element (TRA) are formed from a translucent plastic. System according to one of claims 1 to 7, characterized in that the carrier element (TRA) of the second optical attachment elements (VOP12, VOP22, VOP32) is formed separately and receiving or holding means for receiving or holding the attachment optics. System according to one of Claims 1 to 10, characterized in that each secondary light source (LEN1, LEN2, LEN3 and that the individual secondary optics (LEN1, LEN2, LEN3) are interconnected via their own secondary optics carrier element (STR). System according to claim 11, characterized in that the secondary optics (LEN1, LEN2, LEN3) are formed integrally with the secondary optics carrier element (STR). System according to claim 11 or 12, characterized in that the secondary optics (LEN1, LEN2, LEN3) and / or the secondary optics carrier element (STR) are formed from a translucent plastic. System according to one of claims 11 to 13, characterized in that the secondary optics support element (STR) is formed separately from the secondary optics (LEN1, LEN2, LEN3) and receptacles or holding means for receiving or holding the secondary optics (LEN1, LEN2, LEN3) having. System according to one of claims 1 to 14, characterized in that fastening means (BEF1) for fastening and positioning of the carrier element (TRA) on the mounting element (MON) are provided. A system according to any one of claims 11 to 15, characterized in that secondary optic support member attachment means (BEF2) for attaching and positioning the secondary optic support member (STR) to the mounting member (MON) or for attachment and positioning to the support member (TRA) for the second intent optical elements are provided. System according to one of claims 1 to 10, characterized gekerulzeichnet that each LED light source (LIQ1, LIQ2, LIQ3) in addition to the primary optics in the form of the optical attachment (VOP1, VOP2, VOP3) is associated with secondary optics (LEN1, LEN2, LEN3), and that the individual secondary optics (LEN1, LEN2, LEN3) and the second header optical elements (VOP12, VOP22, VOP32) are interconnected via a common carrier. System according to one of claims 1 to 17, characterized in that each or more LED light sources (LIQ1, LIQ2, LIQ3) is associated with at least one aperture (BLE1, BLE2, BLE3). System according to claim 18, characterized in that the diaphragms are each arranged directly on the light exit surface of the second attachment optical element (VOP12, VOP22, VOP32). System according to claim 18, characterized in that the diaphragms (BLE1, BLE2, BLE3) are connected to one another via a diaphragm support (BTR) and arranged at a distance from the light exit surfaces (LA1 ', LA2', LA3 '). System according to claim 18 or 20, characterized in that the panels (BLE1, BLE2, BLE3) are at least in one direction, preferably substantially parallel to the mounting element (MON), slidably mounted or pivotable about at least one axis. System according to claim 20 and 21, characterized in that the diaphragm support (BTR) at least in one direction, preferably substantially parallel to the mounting element (MON), slidably mounted or pivotable about at least one axis.

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