EP2327926B2

EP2327926B2 - Light unit for vehicles and mounting method

Info

Publication number: EP2327926B2
Application number: EP09177013.1A
Authority: EP
Inventors: Konrad Schürhoff; Heinz-Uwe Spork; Jürgen Schulte; Hans-Gerd Hammelbeck; Christian Erdmann; Jason Franz Endress
Original assignee: Hella KGAA Huek and Co
Current assignee: Hella KGAA Huek and Co
Priority date: 2009-11-25
Filing date: 2009-11-25
Publication date: 2016-12-14
Anticipated expiration: 2029-11-25
Also published as: EP2327926A1; EP2327926B1

Description

The invention relates to a lighting unit for vehicles according to the preamble of patent claim 1.
From the DE 10 2008 013 921 A1 a lighting unit for vehicles is known, on the one hand has a designed as a heat sink first body, on the flat side of a light source (LED light source) is attached. On the other hand, the lighting unit has a second body on which an optical element (lens) is mounted. To bring the first body in a predetermined relative position to the second body are provided as fastening means provided with respective holes cylindrical fastening parts are inserted into the bolt, so that the present in a bore of the second body fastening part between the first body and the second body so is widened, that the first body is held clamped in provided relative position to the second body.
In lighting units, which consist of several each having a light source and an optical element having light modules, the adjustment is relatively expensive. Because for each light module would be done separately, the positioning and fixing of the optical components.
From the DE 10 2004 018 957 A1 is a lighting unit for vehicles is known in which an optical element is held on a reflector via support elements. The support element is integrally connected to the optical element and protrudes in the axial direction of the same. The support member forms a spacer to the reflector. A spring action does not have this support element.
From the DE 570 390 a light unit for vehicles with a light source is known in which a spacer between a reflector and an optical element of the light unit is arranged. The spacer is designed as a helical spring, which allows a resilient support of the optical element at an edge of the reflector.
Object of the present invention is therefore to develop a lighting unit for vehicles such that in a simple and cost-effective manner a precise adjustment or attachment of optical components is guaranteed.
To achieve the object, the invention has the features of claim 1.
According to the invention, a spacer is provided as fastening and / or adjusting means which is arranged between a first body carrying the light source and a second body holding an optical element. The spacer has a release, on the one hand, so that the light emitted by the light source can pass through the spacer in the light emission direction to the optical element. On the other hand, the spacer has a spring element, so that when assembling the first and second body, a predetermined relative position is achieved. After the first body and the second body have been fixed in this predetermined relative position, the lighting unit can be installed in an intended body opening of the vehicle. A readjustment is no longer necessary. The basic idea of the invention is to carry out the adjustment of the optical components automatically during the assembly of the first and second body. Here, the spacer causes a compensation of dimensional tolerances of the components to be mounted. The invention is preferably suitable for light units, which consist of a plurality of light sources and optical elements as optical components, since in one step the adjustment and on the other the fixation can take place. According to the invention, the spacer has at least one locking element, so that the spacer is positively and releasably connectable to the first body. Advantageously, as a result, the spacer can be relatively easily and spent in a defined position to the first body. The final connection or adjustment takes place by connecting the first body to the second body in a further assembly step.
According to a development of the invention, the spacer consists of a plastic material which has a mechanical long-term elongation of greater than 1%. Advantageously, this allows dimensional tolerances of the components to be compensated. Preferably, the spacer is made of a heatable and / or polishable material, so that it can represent a reflective surface. For example, the spacer may be formed as a screen covering the LED circuit board. According to a development of the invention, the release of the spacer may be formed by a tapered in the direction of the light source inclined surface frame, so that on the one hand can increase the output of the light unit luminous flux and on the other hand, a reduction of glare.
According to a development of the invention, preferably a plurality of units formed by the first body and the light source are fastened to the second body by means of a third body. By the plugged spacer, the provided relative position of the first body is automatically taken to the second body or to the optical element. The correct position positioning and fixing preferably a plurality of structural units thus takes place in a single assembly step, which significantly reduces the assembly effort.
According to a development of the invention, the second body and / or the third body made of a highly rigid and high temperature resistant thermoset material. Advantageously, these bodies have an improved thermal expansion behavior, so that the maintenance of the photometric parameters, in particular the observance of the bright / dark boundary, long-term stability is guaranteed.
Further advantages of the invention will become apparent from the further subclaims.
An embodiment of the invention will be explained in more detail with reference to the drawings.
Show it:

Fig. 1: an exploded view of a lighting unit,
Fig. 2: a perspective front view of a holding frame of the lighting unit,
Fig. 3: a front perspective view of a spacer according to a first embodiment,
Fig. 4a: a front perspective view of a spacer according to a second embodiment,
Fig. 4b: a longitudinal section through the spacer according to FIG. 4a .
Fig. 5: a front perspective view of a spacer according to a third embodiment,
Fig. 6: a view of an optical element,
Fig. 7a: an exploded view of a unit, which consists of a spacer, a printed circuit board with LED light source and a heat sink,
Fig. 7b: a view of the assembled unit according to Figure 7a .
Fig. 8a: an exploded view of a structural unit according to an alternative embodiment, which is composed of a spacer, an LED circuit board and a reflector, and
Fig. 8b: a view of a composite unit according to FIG. 8a ,

A lighting unit 1 for vehicles, for example, serves to generate a low-beam function and is arranged in a bow region of a motor vehicle. The lighting unit 1 can be integrated as an elongate lighting unit in a headlight of the vehicle.
How out FIG. 1 can be seen, the lighting unit 1 consists essentially of a plurality of first units 2, each of a first body (reflector body 3, a heat sink 3 '), one equipped with an LED light source 4 printed circuit board 5 and a spacer 6 are formed , a plurality of optical elements 7 assigned in front of the structural unit 2 and an integral second body 8 as well as an integral third body 9.
The second body 8 is designed as an elongate holding frame 8, which has a plurality of opening receptacles 10 for respectively receiving the optical elements 7 from a side arranged in the light emission direction 11 behind the holding frame 8. How better FIG. 2 can be seen, the holding frame 8 has a plurality of Befestigungsdomen 12, so that it is releasably connected by means of screws 13 with the third body 9.
The third body 9 is formed as an elongated support frame whose contour corresponds substantially to the contour of the support frame 8. It has a plurality of opening receptacles 14 for receiving a rear part of the units 2.
Since the lighting unit 1 generates a low beam, which is composed of different partial light images, on the one hand different types of structural units 2 and on the other different types or dimensions of optical elements (lenses 7) are provided. In FIG. 3 a first spacer 6 is shown, which is latchingly connectable to a reflector body 3, see FIG. 8a and FIG. 8b , The spacer 6 has a frame-shaped base part 15, protrude from which to a rear side on the one hand on opposite sides spring elements 16 and on the other on opposite sides or edges locking elements 17. The latching elements 17 are designed such that the spacer 6 can latching with the reflector body 3, on which the circuit board 5 is already located with the LED light source 4, can be connected. The LED light source 4 is thus firmly held on the reflector body 3. The spring elements 16 are designed such that they are resiliently supported against the reflector body 3. A front edge surface 18 of the spacer 6 in the light emission direction 11 serves as a contact surface for the optical element 7 or the holding frame 8 in the mounted state. The edge surface 18 delimits an opening 18 'of the base part 15, through which the light emitted by the LED light source 4 can pass in the direction of the lens 7.
In the assembled state, then the optical element 7 has a defined relative position to the LED light source 4 and the reflector body 3, wherein the spacer 6 can compensate for existing tolerance deviations by means of the spring element 16. The constructional unit 2 thus formed is preferably used for illuminating a far field.
According to the FIGS. 4a and 4b a further spacer 6 'is provided which, starting from a base part 19 on one side at opposite edges projecting locking elements 20 for connection to the heat sink 3' on the one hand and on different edge sides protruding spring elements 21 for support on the heat sink 3 'on the other. On an opposite side of the flat base member 19 is another arranged as a spring tongue spring element 22 is arranged, which presses in the mounting position against the lens 7. This spacer 6 ', together with the LED light source 4 and the circuit board 5 and the heat sink 3', a further unit 2, which serves in conjunction with a corresponding lens 7 to produce a basic light distribution, see FIGS. 7a and 7b , The base part 19 has a release 23 in a central region in which the LED light source 4 is positioned in the mounted position. The release 23 is formed by an inclined surface frame 24 of the base part 19, which is tapered in the direction of the LED light source 4. Since the spacer 6 'has a mirrored surface, in particular the inclined surface frame 24 can contribute to increasing the outgoing luminous flux.
Like from the FIGS. 7a and 7b can be seen, the assembly 2 containing the spacer 6 'formed by the fact that in a first step, the equipped with the LED light source 4 printed circuit board 5 is fastened by screwing 25 on the heat sink 3'. In a further step, the spacer 6 'is then detachably fastened to the edge side of the heat sink 3' at the same.
How out FIG. 5 can be seen, a further spacer 6 "is provided, extending from the spacer 6 'according to the FIGS. 4a and 4b characterized in that it has shorter locking elements 20 ', shorter spring elements 21', 22 '. A base part 19 'of the spacer 6 "has, in accordance with the spacer 6', a release 23 'with an inclined surface frame 24' .This spacer 6" is intended for assemblies 2 for generating an apron light distribution.
For mounting the lighting unit 1, the lenses 7 are positioned in the corresponding opening receptacles 10 of the holding frame 8 in one step. In a further step, the circuit board 5 are positioned together with the LED light source 4 on the reflector body 3 and the heat sink 3 'and then simultaneously or thereafter the corresponding spacer 6, 6', 6 "by latching with the corresponding reflector body 3 or In a further step, the units are then clipped to form the unit 2. In a further step, the units 2 are then under attachment of a front part of the spacer 6, 6 ', 6 "on the lens 7 and The support frame 8 is positioned at the same. In a final assembly step, the support frame 9 is then placed on the back of the units 2 and the support frame 8 and fixed by the screws 13 with the support frame 8. Here, the spring elements 16, 21, 21 ', 22, 22' of the spacers 6, 6 ', 6 "press against the reflector body 3 or heat sink 3' on the one hand and against the lens 7 or the holding frame 8 on the other hand, so that the LED Light source 4 and the reflector body 3 assumes a defined relative position to the lens 7 and the holding frame 8.
The spacers 6, 6 ', 6 "are made of a plastic material which has a long-term elongation of greater than 1% .The spacers 6, 6" consist of a PEI material which can be vapor-deposited and / or polished with aluminum and thus as Can serve screen for the circuit board 5.
The support frame 8 and the support frame 9 are made of a highly rigid and high temperature resistant thermoset material, in particular from the duroplastic Tetradur TD320-025, which is dyed black and is provided with a transparent finish. Advantageously, this material has no sink marks and black high gloss.
Because the spring elements 16, 21, 21 'of the spacers 6, 6', 6 "consist of plastic material and not of metal material, edge chamfering can be dispensed with in the case of the lens 7. An edge breakage of the lenses 7 can thereby be prevented in a simple manner become.

LIST OF REFERENCE NUMBERS

1: light unit
2: first building unit
3, 3 ': Reflector body, heat sink
4: LED light source
5: circuit board
6, 6 ', 6 ": spacer
7: optical element
8th: second body / support frame
9: third body / support frame
10: Opening reception (9)
11: light emission
12: fixing dome
13: screw
14: Opening reception (9)
15: Base part (6)
16: spring element
17: locking element
18, 18 ': Edge surface (6)
19, 19: base
20, 20 ': locking element
21, 21 ': spring element
22, 22 ': spring element
23, 23 ': release
24, 24 ': Sloping surface frame
25: screw

Claims

Light unit for vehicles with a light source (4) being fastened to a first body (3, 3'), having an optic element (7) arranged in light beam direction (11) in front of the light source (4) and being held on a second body (8), the light source (4) being arranged adjusted relative to the optic element (7) with fastening means (6, 6', 6"), a spacer (6, 6', 6") being planned as fastening means and extending between the first body (3, 3') and the second body (8) while forming a cutout (18', 23, 23') for the light source (4), and having a spring element (16, 21, 21', 22, 22') for the resting on the first body (3, 3') or the optic element (7), so that the optic element (7) is held in a given relative position to the first body (3, 3') and the light source (4) by assembling the first and second body (3, 3'; 8), characterized in that the spacer (6, 6', 6") has at least one snapfastening element (17, 20, 20'), such that the spacer (6, 6', 6") can be connected to the first body (3, 3') by snap-fastening.
Light unit according to Claim 1, characterized in that the spring elements (16, 21, 21', 22, 22') and/or the snap-fastening elements (17, 20, 20') protrude from opposing edges of a base part (15, 19, 19') of the spacer (6, 6', 6").
Light unit according to Claim 1 or 2, characterized in that the cutout (18', 23, 23') is limited in direction of the light source (4) by a frame with beveled sides (24, 24').
Light unit according to one of the Claims 1 to 3, characterized in that the spacer (6, 6', 6") is made from a material having a long-term elongation of larger than 1%.
Light unit according to one of the Claims 1 to 4, characterized in that the spacer (6, 6', 6") is made from a material which can be metalized and/ or polished.
Light unit according to one of the Claims 1 to 5, characterized in that the first body (3, 3'), the light source (4) and the spacer (6, 6', 6") form a sub-assembly (2), which is fastened to the second body (8) by means of a third body (9) arranged behind the sub-assembly (2) in the light-beam direction (11).
Light unit according to one of the Claims 1 to 6, characterized in that the second body (8) is embodied as an elongated retention frame and the third body (9) as an elongated carrier frame.
Light unit according to Claim 7, characterized in that the second body (8) and/ or the third body (9) is made from a highly rigid and highly temperature-resistant thermosetting material.