EP2484959A2 - Modular projection light module of a motor vehicle headlamp - Google Patents

Abstract

The projection light module (10) comprises an assembly, which has a light source unit (2) with semiconductor light sources, and another assembly with a lens unit (6). The former assembly is configured to hold the latter assembly in the projection light module. The former assembly is configured to hold in the projection light module without changing an embodiment of the latter assembly or another embodiment of the latter assembly different from the former embodiment.

Description

The present invention relates to a projection light module having at least one first assembly comprising a light source unit having semiconductor light sources and a second assembly having a lens unit, the first assembly being configured to hold the second assembly in the projection light module.

The second assembly is, for example, a lens unit, and the first assembly includes, for example, a light source unit, a shutter unit, and a lens holder unit.

Such a projection light module is known per se and serves to generate a light distribution of the headlamp, which has a cut-off line. This creates the cut-off line as a projection of a Aperture edge of the aperture unit, which is illuminated by a light source of the light source unit. The appearance of headlamps is an important distinguishing feature of motor vehicles. To distinguish their products from products of other motor vehicle manufacturers, they want to be able to make the appearance as free as possible.

While the appearance of a headlight as a whole can be made relatively free, so far have been in the design of the projection light modules restrictions due to technical reasons. Today projection light modules for low beam or high beam or for low beam and high beam (Bi-function) in pre-assembled form in different types of headlights are installed, each using identical projection light modules are used. The use of pre-assembled projection light modules is common in particular with headlamps that are operated with halogen incandescent lamps or with gas discharge lamps as light sources in order to be able to economically produce headlamps in large numbers.

When the headlamps are on and the surroundings are dark, the appearance of headlamps is largely determined by the luminous light emitting surfaces of the lens units of the projection light modules and less by the external shape of the headlamps. A distinction from known appearances can therefore be achieved, for example, via a design of the luminous surfaces of the convergent lens of a projection light module.

Changes in the shape of the condenser lens have always led to large consequential changes in the design of projection light modules in the past, what the constructive effort ago regularly led to a more or less complete redevelopment of the projection light module new headlights. This causes high development costs and manufacturing costs.

Against this background, the object of the invention is to provide a projection light module that allows a great freedom of design of the appearance of equipped with projection light modules headlamps with relatively lower development costs and manufacturing costs.

This object is achieved with the features of claim 1.

The projection light module according to the present invention differs from the per se known projection light module in that the first assembly is adapted to hold, without modification, either a first embodiment of the second assembly or a second embodiment of the second assembly different from the first embodiment in the projection light module, and both to produce a rule-compliant light distribution with the first embodiment as well as with the second embodiment.

These features provide a modularized projection light module that allows for a change in an appearance-relevant second assembly without changing a less relevant first assembly. The invention thus offers a great creative freedom to provide projection light modules with series-individual appearances while largely retaining the advantages of large numbers of the first Assembly. The preservation of the advantages of large numbers represents a major advantage with regard to cost-effective and production-optimized development and production of the projection light modules.

It is preferred that the first assembly in addition to the light source unit has a diaphragm unit and that the second assembly in addition to the lens unit has a lens holder unit.

This refinement has the advantage that the components that are most readily visible and therefore most relevant to the appearance are combined in a second assembly which is variable in appearance, while the components that are not visible are combined to form an assembly that is not to be changed and is moreover embossed by its technical features which does not have to be changed when the design is changed, and which can therefore be produced in large quantities in a production-optimized and cost-optimized manner.

It is also preferable that the second assembly has, in addition to the lens unit, a lens holder unit and a shutter unit.

This embodiment has the advantage that the required for a perfect lighting function of the projection light module adjustment of the diaphragm unit for lens unit within a module, which is manufacturing technology cheaper than when the adjustment of one module relative to another module done when joining the two modules got to. However, this advantage is achieved with the disadvantage that the complexity of the variable in the form of the second component of the projection light module increases while the complexity of the invariable first assembly decreases. This is rather disadvantageous because the desired advantages of the reduced development effort and manufacturing costs are greater, the greater the immutable proportion of the projection light module.

Against this background, a particularly preferred embodiment is characterized in that the first assembly in addition to the light source unit and the aperture unit has a lens holder unit and that the second assembly has a lens unit.

In this embodiment, the immutable portion is particularly large, so that the desired effects occur in a correspondingly large extent.

It is necessary that the lens unit has a defined interface. In a preferred embodiment, this interface is formed by structures of the lens unit which are set up for holding the lens unit and which have a separate component which is different from the convergent lens.

Such a component may, for example, be a lens-holding ring adapted to the shape of the lens, having fastening elements such as threaded holes and / or threaded studs and / or grooves and / or other recesses for attaching the lens unit to the first assembly.

It is also preferable that the lens unit has a plastic lens because plastic lenses in a wide variety of shapes can be manufactured comparatively easily and inexpensively by injection molding. Plastic lenses open up a big one creative freedom at low cost. In addition, plastic lenses are lighter than glass lenses, which contributes to the desired reduction in fuel consumption and emissions of automobiles. The possibility of using plastic lenses instead of glass lenses results in particular when semiconductor light sources are used instead of gas discharge lamps or incandescent lamps, because semiconductor light sources emit substantially less heat with their light. When using semiconductor light sources, a high temperature resistance, as they have glass lenses, no longer of great importance.

Furthermore, it is preferred that structures of the lens unit configured for holding the lens unit are integrated into the plastic material of the plastic lens.

As a result, a defined interface between the convergent lens shaping the optical properties and the appearance of the projection light module and the remainder of the projection light module is provided in a cost-effective manner.

It is also preferable that the plastic lens is a plastic lens produced by a two-component injection molding method in which a blank molded in a first process cycle forms a core of a central portion of the condenser lens, and its final shape is overmolded by molding in a second process cycle Blanks with more plastic results.

A further preferred embodiment provides that structures arranged for holding the lens unit of the lens unit are integrated in the plastic material of the blank or in the other plastic.

As a result, a material adapted in each case to the task to be fulfilled can be used. For the closer part of the optical axis, the optical properties are more important, while for the holder rather mechanical properties such as strength and wear resistance are of importance.

A further preferred refinement is characterized in that the light source unit has a receptacle for the semiconductor light sources, or in that the light source unit has a receptacle for the semiconductor light sources and a control device set up for controlling and / or monitoring the semiconductor light sources, together with for cooling the Having semiconductor light sources arranged heat sinks and arranged for focusing the light of the semiconductor light sources attachment optics.

This embodiment provides a universally applicable light source unit in which components required for the generation of light are combined. This light source unit can be used in every projection light module of the modular projection light module construction kit presented here, which allows the realization of large-scale production.

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

It is understood that the features mentioned above and those yet to be explained below can be used not only in the respectively indicated combination but also in other combinations or alone, without to leave the scope of the present invention.

drawings

Figur 1

das technische Umfeld der Erfindung in der Form einer Anordnung funktioneller Gruppen eines Projektionslichtmoduls in einer perspektivischen Ansicht;

Figur 2

die Anordnung aus der Figur 1 in einer Seitenansicht in einem vertikalen Schnitt,

Figur 3

die Anordnung aus der Figur 2 zusammen mit einer die Baugruppen aus den Figuren 1 und 2 verbindenden Linsenhaltereinheit;

Figur 4

eine Vorderansicht einer Ausgestaltung einer Lichtquellen-Einheit zusammen mit einer ersten Ausführungsform einer Linsen-Einheit einer zweiten Baugruppe;

Figur 5

eine Kombination einer Lichtquellen-Einheit als erster Baugruppe mit einer zweiten Ausführungsform einer Linsen-Einheit einer zweiten Baugruppe;

Figur 6

eine Kombination einer Lichtquellen-Einheit als erster Baugruppe mit einer weiteren Ausführungsform einer Linsen-Einheit einer zweiten Baugruppe;

Figur 7

ein Flussdiagramm als Ausführungsbeispiel eines Verfahrens zur Herstellung einer Funktionselemente aufweisenden Sammellinse; und

Figur 8

ein Beispiel für eine nach diesem Verfahren hergestellte Sammellinse.

Embodiments of the invention are illustrated in the drawings and are explained in more detail in the following description. Show, in schematic form:

FIG. 1

the technical environment of the invention in the form of an arrangement of functional groups of a projection light module in a perspective view;

FIG. 2

the arrangement of the FIG. 1 in a side view in a vertical section,

FIG. 3

the arrangement of the FIG. 2 together with one of the assemblies from the Figures 1 and 2 connecting lens holder unit;

FIG. 4

a front view of an embodiment of a light source unit together with a first embodiment of a lens unit of a second assembly;

FIG. 5

a combination of a light source unit as a first assembly with a second embodiment of a lens unit of a second assembly;

FIG. 6

a combination of a light source unit as a first assembly with another embodiment of a lens unit of a second assembly;

FIG. 7

a flowchart as an embodiment of a method for producing a functional elements having condenser lens; and

FIG. 8

an example of a condensing lens produced by this method.

In this case, the same reference symbols in different figures denote the same or at least functionally identical elements.

In general, one can distinguish four functional groups in a projection light module having semiconductor light sources from a production engineering point of view and from a design point of view: These functional groups are a light source unit, a diaphragm unit, a lens holder unit and a lens unit. The Figures 1 and 2 show arrangements of the light source unit, the diaphragm unit and the lens unit. Fig. 3 shows these three functional groups and additionally a lens holder unit.

In detail, the shows FIG. 1 an arrangement of a light source unit 2, a diaphragm unit 4 and a lens unit 6 of a projection light module 10th

The lens unit 2 has a heat sink 12 made of a material of high thermal conductivity such as aluminum, magnesium, copper or an alloy containing such a metal. In one embodiment, the heat sink 12 has structures such as ribs or pins that increase its heat to the environment emitting surface. On a concavely curved side of the heat sink 12 are separated in two from each other formed rows 14 and 16 arranged as a plurality of light emitting diodes 18 configured semiconductor light sources. The structures, which are not shown, which enlarge the surface of the heat sink 12, are preferably arranged on a rear side of the heat sink 12 which is opposite the concavely curved side. The curvature can be continuous or be replaced by sections tilted against each other.

The first row 14 has four light-emitting diodes 18 arranged closely adjacent to each other. The second row 16 has five light-emitting diodes 18 arranged closely adjacent to one another, so that the overall arrangement of the light-emitting diodes 18 results in a compact unit.

Each light-emitting diode 18 is associated with a designed as a front optics 20 intent optics. The attachment optics 20 bundles the light emitted by the light emitting diodes 18 and preferably operates according to the known principle of total reflection and the refraction at the interfaces between the transparent optical material (for example PMMA (polymethyl methacrylate) or PC (polycarbonate) and the environment.

In the illustrated embodiment, multiple attachment optics 20 are provided as separate attachment optics. Of course, the attachment optics can also be formed in one piece, in which case different regions of the attachment optics form the intentional optics assigned to the different semiconductor light sources 18. Then, a flat heat sink can be used, ie a heat sink without said concave curvature or mutually tilted planes.

The LEDs 18 of each row 14 and 16 can be controlled in groups. It is also possible to control the light-emitting diodes 18 individually in order to turn them on or off individually as needed. The light-emitting diodes 18 can also be dimmed individually or in groups.

especially the Fig. 2 shows that the two planes 14 and 16 are tilted at a certain angle to each other. Alignment may, but does not have to, be such that optical axes 22 of the faceplate attachment optics 20 intersect with plane 22 optical axes 22 of the faceplate optics 20 at a focus point 24 thereafter. Light emerging from the attachment optics 20 is partially shaded by an aperture 26, in some cases light passes the aperture 26. The diaphragm 26 is arranged horizontally with its diaphragm surface 27, wherein the diaphragm surface 27 is at least partially mirrored on the side of the incident light in one embodiment. The silvering is preferably produced with a metallic coating.

As Fig. 1 shows, the diaphragm surface 27 along a light exit direction or light emission direction of the light emitting diodes 18, which coincides approximately with the optical axis 22 of the optical attachment 20, a step or edge 28 which separates two areas of the diaphragm 26 from each other to a law-compliant chiaroscuro Limit.

Both the Fig. 1 as well as the Fig. 2 show that the projection light module 10 in the further beam path has a secondary lens 30 designed as a secondary lens. The secondary optics is preferably embodied as a single aspheric condenser lens 30 with focal lengths between 40 mm and 85 mm. The converging lens 30 may, for lighting reasons at least partially a regular or have irregular textured surface. These structures have a height of about 3 .mu.m-30 .mu.m to the lens surface and serve to influence brightness gradients of the cut-off line and / or color effects in the imaging of the upper edge of the diaphragm.

For correct rotational alignment of the converging lens 30 markings on the lens edge and positive codes are used with the lens holders. The converging lens 30 is biconvex in the illustrated embodiment, but with two different sized radii formed. An optical axis 32 of the converging lens 30 or of the projection light module 10 represents a horizontal plane of the projection light module 10. The diaphragm surface 27 extends essentially along the optical axis 32 or the horizontal plane.

The diaphragm surface 27 may also be slightly tilted relative to the optical axis 32, so that a small angle is formed between the diaphragm surface 27 and the optical axis 32 (cf. FIG. 2 ). The projection light module 10 is preferably constructed in such a way that the heat sink 12 with the planes 14 and 16 is arranged above the optical axis 32 so that the optical axes 22 of the attachment optics 20 intersect the optical axis 32 of the converging lens 30 at an acute angle.

The projection light module 10 serves to generate a light distribution in advance of the motor vehicle. Such a light distribution is generated by the projection light module 10 in the following manner:

The light emanating from the light-emitting diodes 18 and entering the respective associated optical head 20 is bundled in the optical head 20 and propagates preferably along the optical axes 22 of the optical head systems 2.0. The Heat generated during operation of the light-emitting diodes 18 is dissipated via the heat sink 12. The shutter 26 shadows a portion of the light to create a cut-off for the low beam or fog light in front of the vehicle. The remaining portion of the light emerging from the attachment optics 20 impinges on the converging lens 30 and is projected by this with a desired light distribution, taking into account the realization of the cut-off line on the road ahead of the vehicle. The step or edge 28 on the diaphragm 26 thereby generates a legally prescribed for a low beam kink in the projection of the cut-off line in front of the vehicle. As a result, a desired asymmetry of the light distribution with a comparatively far-reaching illumination of the own traffic side while avoiding dazzling of oncoming traffic sets in.

Such generation of a light distribution requires a certain spatial arrangement of each individual unit from the group of the light source unit 2, the diaphragm unit 4 and the lens unit 6 to the respective other two units of the group. To make such a spatial arrangement, the units 2, 4 and 6 are stably connected together. The connection takes place via a lens holder unit 8, of which an embodiment in the Fig. 3 is shown.

Each of the three units 2, 4 and 6 has functional elements which serve for fastening and / or spatial fixing of the respective unit 2, 4, 6 on or in the lens holder unit 8. The functional elements are latching elements and / or clip elements and / or receptacles for pins and / or projections and / or screws and / or rivets and / or in each case complementary Functional elements. In the Fig. 2 The light source unit 2 has functional elements 2a, while the diaphragm unit 4 has functional elements 4a and the lens holder unit 6 has functional elements 6a.

Fig. 3 shows the subject of the Figures 1 and 2 together with a lens holder unit 8 in the assembled state. In the illustrated embodiment, the light source unit 2 is held with functional elements 2b in the lens holder unit 8. The functional elements 2b are complementary to the functional elements 2a. The shutter unit 4 is held in accordance with functional elements 4b in the lens holder unit 8. The functional elements 4b are complementary to the functional elements 4a. The lens unit 6 is held in the lens holder unit 8 with functional elements 6b and 8a. The functional elements 6b are complementary to the functional elements 6a and 8a. The functional elements 8a are, for example, elongate recesses in the lens holder unit 8, which are designed to receive projections 6a of the lens unit in a form-fitting manner. The remaining functional elements 2b, 4b and 6b are complementary to the other functional elements 2a, 4a and 6a functional elements, so that in pairs a locking connection, a screw, a rivet or other compound form-fitting and / or cohesive type, such as by Soldering welding or gluing results.

Of these four functional groups 2, 4, 6, and 8, the lens unit 6 is particularly important for the appearance, since the condenser lens 30 must necessarily always be freely visible from a lighting-technical point of view. The lens holder unit 8 is relevant to the appearance because it is at least partially visible. In addition, due to its supporting function, it is also technically relevant. The aperture unit 4 outweighs the technical relevance. The light source unit 2 serves for receiving and holding the semiconductor light sources, if necessary also for receiving and holding electronics for controlling and / or monitoring the semiconductor light sources, optionally with electrical plug connection, together with one or more heat sinks, and optionally for receiving and holding the optical heads.

These four functional groups can be divided into two subassemblies, of which the first subassembly has rather technically relevant, functional elements, and wherein the second subassembly has at least one element that is more relevant to the appearance. The first subassembly has at least the light source unit having semiconductor light sources and is configured to hold the second subassembly in the projection light module. The second assembly has at least the lens unit. According to the invention, the first assembly is configured to hold, without modification, either a first embodiment of the second assembly or a second embodiment of the second assembly different from the first embodiment in the projection light module, and a conformal light distribution with both the first embodiment and the second embodiment to create.

At the subject of FIGS. 1 to 3 is the interface between the two assemblies either between the light source unit 2 and the composite of the remaining three functional groups 4, 6 and 8, or the interface is between the lens unit 6 and the remaining in this case three functional assemblies 2, 4 and 8. In the In the first alternative, the second subassembly accordingly has, in addition to the lens unit 6, a lens holder unit 8 and a shutter unit 4. In the second alternative, the first assembly in addition to the light source unit 2 on a shutter unit 4 and a lens holder unit 8.

Fig. 4 shows a front view of an embodiment of a light source unit 2 together with a first embodiment of a lens unit 6 in the form of a converging lens 30. The light source module 2 has in the illustrated embodiment holding structures 2.1, which are adapted to a mounting both the aperture Unit 4 and the lens holder unit 8 to allow. In the embodiment, in the Fig. 4 1, the holding structures 2.1 have a first substructure 2.2 and a second substructure 2.3. The first substructure serves for fastening the lens holder unit 8. The second substructure serves for fastening the panel unit 4. For this purpose, both substructures 2.1 and 2.2 have functional elements 2a, as described above with reference to FIGS Fig. 2 have already been explained.

The object of Fig. 4 is used in particular for realizing an embodiment in which the first assembly has an aperture unit 4 in addition to the light source unit 2 and in which the second assembly has a lens holder unit 8 in addition to the lens unit 6. In this embodiment, the first assembly and in particular the light source unit 2 is designed such that lens units 6 and lens holder units 8 of different designs can be attached to the light source unit 2. The FIGS. 4 to 6 show such combinations of the same light source unit 2 with different lens units 6.

Fig. 4 shows a combination of a light source unit 2 as a first assembly with an embodiment of a second assembly whose lens unit 6 has a circle-limited converging lens 30.

Fig. 5 shows a combination of a light source unit 2 as a first assembly with an embodiment of a second assembly whose lens unit 6 has a conical lens 30 limited by a rectangle.

Fig. 6 shows a combination of a light source unit 2 as a first assembly with an embodiment of a second assembly whose lens unit 6 has a converging lens 30, whose shape of the basic forms of Fig. 4 and 5 differs freely and thus illustrates the available design scope.

The in the FIGS. 4 to 6 presented combinations are characterized in that the light source unit 2 is designed so that it can be combined with other embodiments of lens units 6 and lens holder units 8 without changes. The various embodiments of the lens units and the lens holder units, together with the first assembly composed of the light source unit and the shutter unit, form a modular system from which projection light modules 10 having different appearances can be assembled. In this case, the first module represents the component that is more technically embossed and the same for all projection light modules 10, while the second module represents a variable design component that rather shapes the appearance of the projection light module.

In one embodiment, the light source unit together with the aperture unit forms a not assembled at headlight or little visible and thus not relevant to the appearance of the first assembly, while the lens holder unit forms a preassembled design unit together with the lens unit , This corresponds, for example, to the subject matter of FIGS. 4 to 6 ,

In a further embodiment, the lens unit, the lens holder unit and the diaphragm unit are combined to form a second module. This corresponds, for example, to the subject matter of Figures 2 and 3 wherein the interface between the first assembly and the second assembly then passes between the light source unit 2 and the lens holder unit 8. The position of the aperture unit relative to the lens unit must be adjusted as a rule. The summary of the lens unit, with the lens holder unit and the diaphragm unit to a second assembly in this context has the advantage that the adjustment during the pre-assembly of the second module can be done. This is easier to manufacture than if the adjustment takes place during assembly of the first module with the second module.

Particularly high is the. Constant parts of a projection light module modular system, when the light source unit, the diaphragm unit and the Blendehalter unit are combined to form a fixed, first assembly. This also corresponds, for example, to the subject matter of Figures 2 and 3 However, the interface between the first assembly and the second assembly then extends between that of the lens holder assembly 8 and the lens unit 6.

In these embodiments, it is necessary that the lens unit has a defined interface with functional elements, as in the form of functional elements 6a in connection with the Figures 2 and 3 have been explained.

These functional elements, for example the functional elements 6a from the Figures 2 and 3 are in a preferred embodiment, a part of a mechanically connected to the condenser lens 30 and the condenser lens 30 holding part, such as a lens holder ring or a lens holding frame, which circulates the outer contour of the condenser lens 30, for example, so that the condenser lens of the ring or Frame is framed and held. Alternatively, however, a frameless mechanical support may be used, in which the condenser lens 30 is connected, for example, with two metallic spacers, which in turn are adapted to be connected to the lens holder unit.

In an alternative embodiment, the functional elements of the lens unit used for connecting the lens holder unit to the lens unit are an integral part of the lens, which can be produced, for example, in the case of plastic lenses by the possibilities of plastic injection molding. Here, the functional elements are formed integrally formed with the optically active parts of the converging lens in an injection molding process to the optically active parts.

In a particularly preferred embodiment, these functional elements are part of a transparent or non-transparent component of a lens unit produced by a two-component injection molding process.

Conventionally, collecting lenses 30 are made of plastic in one piece, in particular in a process cycle, by injection molding. Due to the relatively large thickness in the center of the converging lenses 30, they must be sprayed, cooled and demolded in an extremely complicated process and very slowly, as otherwise air inclusions in the plastic material, shrinkage of the material, deformation of the workpiece and / or so-called vacuoles may occur. With a center lens approximately 30 mm thick, the cycle time for its production in a process cycle is about 18 minutes. In addition, the quality of the converging lenses 30 produced by the known method is not optimal in terms of shape, contour and surface structure, because despite the greatest care in injection molding due to the large thickness of the converging lenses 30 errors in an acceptable cycle time can not be completely prevented.

Another disadvantage of manufacturing in one process cycle is that the possible shape of the converging lenses 30 is extremely limited. For this reason, the converging lenses 30 produced in one process cycle usually have a very simple shape. A more flexible design of the condenser lens with regard to its shape and contour and the injection molding of functional parts (eyelets, snap hooks, domes, bearing surfaces, etc.) is possible only to a limited extent with a manufacturing process in a process cycle.

FIG. 7 1 shows a flowchart as an exemplary embodiment of a method for producing a collecting lens 30 having functional elements 6 a. After a start of the method in step 32, in a first step 34, which corresponds to a first process cycle, a blank of the converging lens 30 molded from plastic. The blank does not yet correspond in its dimensions, its shape and its contour to the final converging lens 30. In particular, the blank in the center has a smaller thickness than the finished converging lens 30. If, for example, the finished converging lens 30 have a thickness in the center of about 24 mm should, for example, the blank could have a thickness in the center of only 12 mm. Even with regard to the surface finish of the blank does not yet meet the requirements of the finished positive lens 30. So it is, for example, conceivable that the blank on its surface incidence, scratches or similar defects. By compared to the finished converging lens 30 smaller dimensions of the blank and the lower demands on the quality of the surfaces of the blank can be injected much faster from plastic than a converging lens produced in a train.

In a second step or process cycle 36, the blank produced in the first process cycle 34 is at least partially encapsulated with an additional layer of plastic. The overmolding with an additional plastic layer serves on the one hand to produce the desired dimensions, as well as the desired shape and contour of the converging lens 30. Thus, for example, it is conceivable to spray an additional layer both on the front side and on the rear side of the blank, which is about 6 mm thick in the center of the blank, so that the roughly 12 mm thick blank in the center together with the two approximately 6 mm thick additional layers of plastic leading to the front and back of the blank to form a finished converging lens with a thickness in the center of about 24 mm. The other dimensions, the shape and the contour of the finished converging lens 30 can by spraying additional Plastic layers are produced on the blank in the second process cycle 36. Furthermore, the extrusion coating of the blank with an additional plastic layer serves to achieve the desired surface quality of the finished converging lens 30. The additional plastic layer sprayed onto the blank compensates for unevenness in the surface of the blank, penetrates even the finest scratches, notches and quirks in the surface of the blank and fills them completely.

Due to the relatively small thickness of the second Prozesstakt 36 additionally sprayed plastic layers, they can be manufactured with the required accuracy and quality in a relatively short time.

After the second process cycle 36, the finished converging lens 7 has the desired dimensions, in particular the desired thickness and the desired shape and contour with the integrally formed functional elements. The method then ends in a step 38.

An example of a condensing lens produced by this method is shown in FIG FIG. 8 shown. FIG. 8 shows a section through such a converging lens along the line VIII-VIII of the Fig. 2 , A blank 40 injection-molded in the first process cycle forms a core of a central region of the condenser lens 30. The blank 40 has at its ends the functional elements 6a already explained above, which serve to connect the condenser lens 30 to the lens holder unit 8. In the second process step, the final shape of the converging lens 30 is produced by molding the blank 40 with further plastic 42. Alternatively to this procedure, in which the Functional elements 6a have been generated in the first process step, the functional elements 6a can also be generated in the second process step.

Claims (10)

A projection light module (10) having at least one first assembly comprising a light source unit (2) comprising semiconductor light sources and a second assembly having a lens unit (6), the first assembly being adapted to mount the second assembly in the first assembly Holding the projection light module (10), characterized in that the first assembly is adapted to hold without modification either a first embodiment of the second assembly or a second embodiment of the second assembly different from the first embodiment in the projection light module (10) and both to produce a rule-compliant light distribution with the first embodiment as well as with the second embodiment. Projection light module (10) according to claim 1, characterized in that the first assembly in addition to the light source unit (2) has a diaphragm unit (4) and that the second assembly in addition to the lens unit (6) has a lens holder unit (8 ) having. Projection light module (10) according to claim 1, characterized in that the second assembly in addition to Lens unit (6) has a lens holder unit (8) and a diaphragm unit (4). Projection light module (10) according to claim 1, characterized in that the first assembly in addition to the light source unit (2) comprises a diaphragm unit (4) and a lens holder unit (8). Projection light module (10) according to claim 4, characterized in that for holding the lens unit (6) arranged structures of the lens unit (6) have a separate, different from the converging lens (30) component. Projection light module (10) according to one of the preceding claims, characterized in that the lens unit (6) comprises a plastic lens. Projection light module (10) according to claim 6, characterized in that for holding the lens unit (6) arranged structures (6a) of the lens unit (6) are integrated into the plastic material of the plastic lens. Projection light module (10) according to claim 6 or 7, characterized in that the plastic lens is a plastic lens produced by a 2-component injection molding process, wherein a blank (40) molded in a first process cycle comprises a core of a central region of the condenser lens (30). forms, and their final shape is obtained by overmolding the blank (40) with further plastic (42) in a second process cycle. Projection light module according to claim 8, characterized in that arranged for holding the lens unit (6) structures (6a) of the lens unit (6) in the Plastic material of the blank or in the other plastic (42) are integrated. Projection light module (10) according to one of claims 6 to 8, characterized in that the light source unit (2) has a receptacle for the semiconductor light sources, or that the light source unit (2) has a receptacle for the semiconductor light sources and / or or monitoring the semiconductor light sources configured control device, together with arranged for cooling the semiconductor light sources heat sinks and for focusing the light of the semiconductor light sources equipped auxiliary optics (20).

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