EP2708798A1 - Lighting module for a motor vehicle - Google Patents

Lighting module for a motor vehicle Download PDF

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Publication number
EP2708798A1
EP2708798A1 EP20130183189 EP13183189A EP2708798A1 EP 2708798 A1 EP2708798 A1 EP 2708798A1 EP 20130183189 EP20130183189 EP 20130183189 EP 13183189 A EP13183189 A EP 13183189A EP 2708798 A1 EP2708798 A1 EP 2708798A1
Authority
EP
European Patent Office
Prior art keywords
reflectors
lens
lighting module
light
module
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP20130183189
Other languages
German (de)
French (fr)
Other versions
EP2708798B1 (en
Inventor
Antoine De Lamberterie
Ziyed Thabet
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Valeo Vision SAS
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Valeo Vision SAS
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Filing date
Publication date
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Publication of EP2708798A1 publication Critical patent/EP2708798A1/en
Application granted granted Critical
Publication of EP2708798B1 publication Critical patent/EP2708798B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/25—Projection lenses
    • F21S41/26—Elongated lenses
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141—Light emitting diodes [LED]
    • F21S41/147—Light emitting diodes [LED] the main emission direction of the LED being angled to the optical axis of the illuminating device
    • F21S41/148—Light emitting diodes [LED] the main emission direction of the LED being angled to the optical axis of the illuminating device the main emission direction of the LED being perpendicular to the optical axis
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/29—Attachment thereof
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/30—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by reflectors
    • F21S41/32—Optical layout thereof
    • F21S41/321—Optical layout thereof the reflector being a surface of revolution or a planar surface, e.g. truncated
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/30—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by reflectors
    • F21S41/32—Optical layout thereof
    • F21S41/33—Multi-surface reflectors, e.g. reflectors with facets or reflectors with portions of different curvature
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/30—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by reflectors
    • F21S41/32—Optical layout thereof
    • F21S41/36—Combinations of two or more separate reflectors
    • F21S41/365—Combinations of two or more separate reflectors successively reflecting the light
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/40—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by screens, non-reflecting members, light-shielding members or fixed shades
    • F21S41/43—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by screens, non-reflecting members, light-shielding members or fixed shades characterised by the shape thereof
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making

Definitions

  • the invention relates to a lighting module for a motor vehicle, in particular for generating a large optical beam cut from a plurality of sources.
  • a motor vehicle lighting module with a plurality of concave reflectors, each comprising a light source in its concavity, in order to combine the light beams from each reflector to form an optical beam.
  • the document EP 1 610 057 B1 describes such a module provided with three reflectors such that the edges of the reflectors are placed against each other. The beams from these reflectors then combine so that a central module ensures the luminous flux at the center of the generated beam while the two lateral modules provide the luminous flux on the edges of said generated beam.
  • this document also discloses the use of a folder folding the optical beam from a collector to obscure the upper portion of the optical beam generated by this module and thus avoid dazzling drivers of vehicles crossing or preceding this motor vehicle.
  • the present invention results from the observation that such a module is perfectible.
  • the optical beam generated by such a module has significant intensity variations, for example between the center and the edges of the beam which have maximums specific to each light source. There is therefore no decrease in homogeneous intensity from a maximum intensity located at the center of the beam.
  • the efficiency of such a module is insufficient to allow the generation of a light beam of satisfactory intensity with optical resources limited to, for example, two light-emitting diodes with a power of 3 W. This is due the fact that the reflectors are relatively open and do not allow to collect a maximum amount of flow.
  • the present invention aims to solve at least one of these problems. It results from a finding peculiar to the invention according to which, in order to optimize the efficiency in the transmission of the optical beam generated by a source, it It is advisable to place the latter at the focus of a convergent reflector so that a maximum of optical radiation emitted by this source is collected by this reflector and transmitted to a lens at the output of the module. Indeed a so-called convergent reflector converges the reflected light rays, and therefore has a better efficiency.
  • the present invention relates to a lighting module for a motor vehicle headlamp capable of forming a large light beam cut.
  • This module comprises optical elements formed by an exit lens and a plurality of concave reflectors associated with a folder having a reflective face for folding light beams generated by light sources located in the concavities of the reflectors.
  • the lens is a toric, and these optical elements are arranged so as to converge the light beams generated by said light sources into focusing points prior to the transmission of these light beams by the output lens.
  • the module comprises two reflectors oriented towards each other.
  • Such a module has many advantages.
  • it uses reflectors collecting a large part of the optical radiation emitted by light sources located in their homes. By concentrating this radiation at a point of focus before it is transmitted by the output lens, such a module makes it possible to generate lighting lamps, typically fog lamps, with two sources of limited power, for example two light emitting diodes. power less than or equal to 3W.
  • such a module makes it possible to form a single beam, from several beams, having a particularly satisfactory homogeneity.
  • a single beam has a homogeneous decay from a central portion, which improves the comfort of drivers of a vehicle equipped with such a module.
  • the lighting module is characterized in that the focusing points are located on a line of foci of the toric lens.
  • the lighting module is characterized in that the folder follows, partially or completely, the line of foci of the lens.
  • the reflectors are based on an ellipsoid shape having two focal points, the light source of a reflector being located in a first focus of that ellipsoid and the focusing point being located in a second focus of the same ellipsoid.
  • the axis of a reflector passing through the first and second focus of the ellipsoid at its base, forms a non-zero angle with the optical axis of the lens.
  • the reflector has a plane of symmetry allowing its installation on both sides of a vehicle.
  • the total lateral opening of the optical beam is between 40 degrees and 100 degrees.
  • the invention also relates to a method for manufacturing a lighting module for a motor vehicle headlamp, capable of forming a large cut-off light beam, provided with optical elements comprising an exit lens and a plurality of concave reflectors associated with a folder having a reflective face for folding light beams generated by light sources located in the concavities of the reflectors.
  • the method comprises the step of arranging these optical elements so as to converge the light beams generated by said light sources into focusing points prior to the transmission of these light beams by the output lens in accordance with FIG. a module as defined above.
  • a lighting module 100 for motor vehicle headlamp that is to say able to form a wide light beam 101 cut.
  • a beam 101 is wide when it has a total lateral opening of between 40 degrees and 100 degrees, ie a half-opening, with reference to the longitudinal axis of symmetry of the vehicle, between 25 degrees and 50 degrees, the opening (or half-opening) being defined for a minimum intensity of about 100 candelas.
  • Figures 1 and 2 represent views in vertical and horizontal sections respectively of such a module 100 at a reflector 102, these cuts being made in vertical and horizontal planes passing through the source 104 and the focusing point 106 of the light emitted by this source 104 and reflected by the reflector 102.
  • this focusing point 106 is located upstream of an output lens 108 - toric lens - so that the optical beam emitted by the source 104 passes through the lens 108 after concentrating at this point of focusing.
  • a focusing point 106 situated upstream of the lens 108 it is possible to concentrate a large part of the light emitted by the source 104.
  • different rays 110, 112 and 114 emitted by the source 104 are represented in their optical path from the source 104 to the broad beam 101 through the focusing point 106.
  • This arrangement of the optical elements is obtained by considering that the source 104 is located at the first focus of an ellipsoid serving as a base for generating the reflector 102, the second focus of the ellipsoid being placed at the point of focusing.
  • the entire module 100 is constructed using a symmetry between the different reflectors.
  • this symmetry is obtained with respect to a vertical plane 200 ( Figure 2 ) passing through the optical axis of the toric lens 108, which is constituted in this embodiment of the intersection between the vertical plane 200 and a horizontal plane passing through the source 104.
  • the optical axis of the toric lens 108 is for example materialized by the axis Oy on the Figures 3 and 4 .
  • the reflectors 102 and 102 ', the light sources 104 and 104' and the focusing points 106 and 106 ' are symmetrical with respect to the plane 200.
  • the segments 202 joining the source 104 and the point 106, and 202 'joining the source 104' and the point 106 ' form an angle ⁇ with the median plane 200.
  • the line 118 of the foci of the lens 108 which includes inter alia points 106 and 106 'of focusing reflectors 102 and 102'.
  • the lens 108 being toric, the beams 101 and 101 'are focused at infinity in the vertical direction, while in the horizontal direction they undergo a spreading, to enable them to fulfill their lighting function.
  • the reflectors 102 and 102 ' are associated with a flat plate 120 that is substantially horizontal as represented on the Figures 3 and 4 .
  • the plane of this plate 120 passes preferably, but not necessarily, substantially through the centers of the light sources 104 and 104 '.
  • the reflectors 102 and 102 'are located above the plate 120 and the upper face of the plate 120 is reflective to fold the beam beams from the reflectors 102 and 102'.
  • the reflective plate 120 is frequently called “bender” and has a front end edge adapted to form the cut in the light beam, that is to say the upper limit above which there is no light rays.
  • the cut is horizontal and the area illuminated by the beam from the reflectors 102 and 102 'is located below a horizontal line.
  • FIGS. 3 and 4 are represented two perspective views of the reflectors 102 and 102 'obtained according to the arrangements described above with the aid of an embodiment using a reference (O, x, y, z) where the axis Oy is the optical axis of the module.
  • the toric lens 108 has a horizontal radius of curvature of 80 mm and its center has coordinates (0, -30 mm, 0).
  • the center of the toric lens 108 is defined by the center of curvature in the plane Oxy of the input and output faces of the lens 108.
  • Such a lens has a line of foci 118 coincident with the edge of the folder (not shown) , the distance between this line 118 of foci is the entrance face of the lens 108 being a draw T 28.8mm.
  • the folder is extruded (from 4mm + y in the example of Figures 3 and 4 ) in a shape that follows the two ascents of light at the center of the beam. This shape folds the images in the center of the beam above the cut that come from the association of the two points of focus of the two sources.
  • the Figure 7 shows the evolution at the center of the beam while the Figure 8 shows the distribution of light on the surface of the folder, this figure also highlighting the importance of the depth of the folder (32mm in the previous example) to collect the maximum flow).
  • This Figure 8 shows a view from above of the light concentration projected by the mirrors on the folder (the axes are graduated in millimeters horizontally and vertically). We see in particular that the maximum light is projected on the edge of the folder, but we also see that a significant amount of light reaches the folder upstream of the edge.
  • This part of the beam results from the edges of the reflectors 102 and 102 '( Fig. 3 ) which are modified by choosing a focal length different from the focal length for the ellipsoid used as a basis for the realization of the reflectors so as to straighten the rise of light by focusing slightly before the second focus of the reflector.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Optics & Photonics (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Abstract

The module (100) has optical elements including a toric output lens (108) and concave reflectors (102, 102') associated with a folder having a reflecting face for folding light beams generated by light sources i.e. LEDs (104, 104') located in the concave reflectors. The optical elements are arranged to converge the light beams generated by the LEDs at focal points (106, 106') prior to the transmission of the light beams by the output lens, where the concave reflectors are oriented towards each other. An independent claim is also included for a method for manufacturing a lighting module for forming a wide light beam in a headlight of a motor vehicle.

Description

L'invention est relative à un module d'éclairage pour véhicule automobile, notamment destiné à générer un large faisceau optique à coupure à partir d'une pluralité de sources.The invention relates to a lighting module for a motor vehicle, in particular for generating a large optical beam cut from a plurality of sources.

Il est connu de former un module d'éclairage de véhicule automobile avec une pluralité de réflecteurs concaves, comprenant chacun une source lumineuse dans sa concavité, afin de combiner les faisceaux lumineux issus de chaque réflecteur pour former un faisceau optique.It is known to form a motor vehicle lighting module with a plurality of concave reflectors, each comprising a light source in its concavity, in order to combine the light beams from each reflector to form an optical beam.

A titre d'exemple, le document EP 1 610 057 B1 décrit un tel module muni de trois réflecteurs tels que les bords des réflecteurs sont placés les uns contre les autres. Les faisceaux issus de ces réflecteurs se combinent alors de telle sorte qu'un module central assure le flux lumineux au centre du faisceau généré tandis que les deux modules latéraux assurent le flux lumineux sur les bords dudit faisceau généré.For example, the document EP 1 610 057 B1 describes such a module provided with three reflectors such that the edges of the reflectors are placed against each other. The beams from these reflectors then combine so that a central module ensures the luminous flux at the center of the generated beam while the two lateral modules provide the luminous flux on the edges of said generated beam.

Par ailleurs ce document divulgue également l'utilisation d'une plieuse repliant le faisceau optique issu d'un collecteur afin d'occulter la partie supérieure du faisceau optique généré par ce module et éviter ainsi d'éblouir des conducteurs de véhicules croisant ou précédant ce véhicule automobile.Furthermore, this document also discloses the use of a folder folding the optical beam from a collector to obscure the upper portion of the optical beam generated by this module and thus avoid dazzling drivers of vehicles crossing or preceding this motor vehicle.

La présente invention résulte de la constatation qu'un tel module est perfectible. Notamment, il apparaît que le faisceau optique généré par un tel module a des variations d'intensité notables, par exemple entre le centre et les bords du faisceau qui présentent des maximums propres à chaque source lumineuse. Il n'y a donc pas une décroissance d'intensité homogène à partir d'une intensité maximale située au centre du faisceau. On peut de plus observer une décroissance de lumière au voisinage des directions correspondant aux intersections entre les collecteurs.The present invention results from the observation that such a module is perfectible. In particular, it appears that the optical beam generated by such a module has significant intensity variations, for example between the center and the edges of the beam which have maximums specific to each light source. There is therefore no decrease in homogeneous intensity from a maximum intensity located at the center of the beam. We can also observe a decrease in light near the directions corresponding to the intersections between the collectors.

De plus, le rendement d'un tel module est insuffisant pour permettre la génération d'un faisceau lumineux d'une intensité satisfaisante avec des ressources optiques limitées à, par exemple, deux diodes électroluminescentes d'une puissance de 3 W. Ceci est dû au fait que les réflecteurs sont relativement ouverts et ne permettent pas de collecter une quantité maximale de flux.In addition, the efficiency of such a module is insufficient to allow the generation of a light beam of satisfactory intensity with optical resources limited to, for example, two light-emitting diodes with a power of 3 W. This is due the fact that the reflectors are relatively open and do not allow to collect a maximum amount of flow.

La présente invention vise à résoudre au moins un de ces problèmes. Elle résulte d'une constatation propre à l'invention selon laquelle, pour optimiser le rendement dans la transmission du faisceau optique généré par une source, il convient de placer cette dernière au foyer d'un réflecteur convergent afin qu'un maximum de rayonnement optique émis par cette source soit collecté par ce réflecteur et transmis à une lentille en sortie du module. En effet un réflecteur dit « convergent » fait converger les rayons lumineux réfléchis, et a donc une meilleure efficacité.The present invention aims to solve at least one of these problems. It results from a finding peculiar to the invention according to which, in order to optimize the efficiency in the transmission of the optical beam generated by a source, it It is advisable to place the latter at the focus of a convergent reflector so that a maximum of optical radiation emitted by this source is collected by this reflector and transmitted to a lens at the output of the module. Indeed a so-called convergent reflector converges the reflected light rays, and therefore has a better efficiency.

C'est pourquoi la présente invention concerne un module d'éclairage pour projecteur de véhicule automobile apte à former un large faisceau lumineux à coupure. Ce module comporte des éléments optiques formés par une lentille de sortie et par une pluralité de réflecteurs concaves associés à une plieuse présentant une face réfléchissante destinée à replier des faisceaux lumineux générés par des sources lumineuses situées dans les concavités des réflecteurs. La lentille est torique, et ces éléments optiques sont agencés de manière à faire converger les faisceaux lumineux générés par lesdites sources lumineuses en des points de focalisation préalablement à la transmission de ces faisceaux lumineux par la lentille de sortie.This is why the present invention relates to a lighting module for a motor vehicle headlamp capable of forming a large light beam cut. This module comprises optical elements formed by an exit lens and a plurality of concave reflectors associated with a folder having a reflective face for folding light beams generated by light sources located in the concavities of the reflectors. The lens is a toric, and these optical elements are arranged so as to converge the light beams generated by said light sources into focusing points prior to the transmission of these light beams by the output lens.

Selon l'invention, le module comprend deux réflecteurs orientés l'un vers l'autre.According to the invention, the module comprises two reflectors oriented towards each other.

Un tel module présente de nombreux avantages. Notamment il met en oeuvre des réflecteurs collectant une partie importante du rayonnement optique émis par des sources lumineuses situées en leurs foyers. En concentrant ce rayonnement en un point de focalisation préalablement à sa transmission par la lentille de sortie, un tel module permet de générer des feux d'éclairage, typiquement des feux de brouillard, avec deux sources de puissance limitée, par exemple deux diodes électroluminescentes de puissance inférieure ou égale à 3W.Such a module has many advantages. In particular, it uses reflectors collecting a large part of the optical radiation emitted by light sources located in their homes. By concentrating this radiation at a point of focus before it is transmitted by the output lens, such a module makes it possible to generate lighting lamps, typically fog lamps, with two sources of limited power, for example two light emitting diodes. power less than or equal to 3W.

Par ailleurs un tel module permet de former un faisceau unique, à partir de plusieurs faisceaux, présentant une homogénéité particulièrement satisfaisante. De fait, un tel faisceau unique présente une décroissance homogène à partir d'une partie centrale, ce qui améliore le confort des conducteurs d'un véhicule équipé d'un tel module.Moreover, such a module makes it possible to form a single beam, from several beams, having a particularly satisfactory homogeneity. In fact, such a single beam has a homogeneous decay from a central portion, which improves the comfort of drivers of a vehicle equipped with such a module.

Dans une réalisation, le module d'éclairage est caractérisé en ce que les points de focalisation sont situés sur une ligne de foyers de la lentille torique.In one embodiment, the lighting module is characterized in that the focusing points are located on a line of foci of the toric lens.

Selon une réalisation, le module d'éclairage est caractérisé en ce que la plieuse suit, partiellement ou totalement, la ligne de foyers de la lentille.According to one embodiment, the lighting module is characterized in that the folder follows, partially or completely, the line of foci of the lens.

Dans une réalisation, les réflecteurs sont basés sur une forme d'ellipsoïde présentant deux foyers, la source lumineuse d'un réflecteur étant située dans un premier foyer de cet ellipsoïde et le point de focalisation étant situé dans un second foyer de ce même ellipsoïde.In one embodiment, the reflectors are based on an ellipsoid shape having two focal points, the light source of a reflector being located in a first focus of that ellipsoid and the focusing point being located in a second focus of the same ellipsoid.

Dans une réalisation, l'axe d'un réflecteur, passant par le premier et le second foyer de l'ellipsoïde à sa base, forme un angle non nul avec l'axe optique de la lentille.In one embodiment, the axis of a reflector, passing through the first and second focus of the ellipsoid at its base, forms a non-zero angle with the optical axis of the lens.

Selon une réalisation, le réflecteur présente un plan de symétrie permettant son installation des deux côtés d'un véhicule.According to one embodiment, the reflector has a plane of symmetry allowing its installation on both sides of a vehicle.

Selon une réalisation, l'ouverture latérale totale du faisceau optique est comprise entre 40 degrés et 100 degrés.In one embodiment, the total lateral opening of the optical beam is between 40 degrees and 100 degrees.

L'invention concerne également un procédé de fabrication d'un module d'éclairage pour projecteur de véhicule automobile, apte à former un large faisceau lumineux à coupure, muni d'éléments optiques comprenant une lentille de sortie et une pluralité de réflecteurs concaves associés à une plieuse présentant une face réfléchissante destinée à replier des faisceaux lumineux générés par des sources lumineuses situées dans les concavités des réflecteurs.The invention also relates to a method for manufacturing a lighting module for a motor vehicle headlamp, capable of forming a large cut-off light beam, provided with optical elements comprising an exit lens and a plurality of concave reflectors associated with a folder having a reflective face for folding light beams generated by light sources located in the concavities of the reflectors.

Selon l'invention, le procédé comprend l'étape d'agencer ces éléments optiques de manière à faire converger les faisceaux lumineux générés par lesdites sources lumineuses en des points de focalisation préalablement à la transmission de ces faisceaux lumineux par la lentille de sortie conformément à un module tel que défini précédemment.According to the invention, the method comprises the step of arranging these optical elements so as to converge the light beams generated by said light sources into focusing points prior to the transmission of these light beams by the output lens in accordance with FIG. a module as defined above.

D'autres avantages de l'invention apparaîtront à la lumière de la description d'une réalisation de l'invention effectuée ci-dessous, à titre illustratif et non limitatif, en référence aux Figures ci-jointes sur lesquelles :

  • La Figure 1 représente schématiquement une vue en coupe verticale d'un module réalisé conformément à l'invention ;
  • La Figure 2 représente schématiquement une vue en coupe horizontale d'un module réalisé conformément à l'invention ;
  • Les Figures 3 et 4 représentent schématiquement des vues en perspective des éléments optiques d'un module réalisé conformément à l'invention ;
  • Les Figures 5A, 5B et 5C représentent en perspective différentes étapes de réalisation d'un réflecteur conforme à l'invention ;
  • Les Figures 6 à 9 représentent des courbes isolux de différentes configurations du module réalisé conformément à l'invention, et
  • La Figure 10 représente la trace du faisceau lumineux émis par un module réalisé conformément à l'invention sur un écran perpendiculaire à l'axe optique du module.
Other advantages of the invention will emerge in the light of the description of an embodiment of the invention made below, by way of illustration and not limitation, with reference to the attached figures in which:
  • The Figure 1 schematically represents a vertical sectional view of a module made according to the invention;
  • The Figure 2 schematically represents a horizontal sectional view of a module made according to the invention;
  • The Figures 3 and 4 schematically represent perspective views of the optical elements of a module made in accordance with the invention;
  • The Figures 5A, 5B and 5C represent in perspective different stages of realization of a reflector according to the invention;
  • The Figures 6 to 9 represent isolux curves of different configurations of the module produced in accordance with the invention, and
  • The Figure 10 represents the trace of the light beam emitted by a module made according to the invention on a screen perpendicular to the optical axis of the module.

Dans la présente description, des éléments identiques ou ayant des fonctions similaires peuvent être représentés sur différentes Figures avec un même numéro de référence.In the present description, elements identical or having similar functions can be represented in different Figures with the same reference number.

En référence aux Figures 1 et 2 est décrite la réalisation d'un module 100 d'éclairage pour projecteur de véhicule automobile conforme à une réalisation de l'invention, c'est-à-dire apte à former un large faisceau lumineux 101 à coupure. A cet effet, on considère qu'un faisceau 101 est large lorsqu'il présente une ouverture latérale totale comprise entre 40 degrés et 100 degrés, soit encore une demi-ouverture, en référence à l'axe de symétrie longitudinal du véhicule, comprise entre 25 degrés et 50 degrés, l'ouverture (ou la demi-ouverture) étant définie pour une intensité minimale d'environ 100 Candelas.With reference to Figures 1 and 2 is described the embodiment of a lighting module 100 for motor vehicle headlamp according to an embodiment of the invention, that is to say able to form a wide light beam 101 cut. For this purpose, it is considered that a beam 101 is wide when it has a total lateral opening of between 40 degrees and 100 degrees, ie a half-opening, with reference to the longitudinal axis of symmetry of the vehicle, between 25 degrees and 50 degrees, the opening (or half-opening) being defined for a minimum intensity of about 100 candelas.

Plus précisément les Figures 1 et 2 représentent des vues en coupes verticale et horizontale respectivement d'un tel module 100 au niveau d'un réflecteur 102, ces coupes étant effectuées dans des plans vertical et horizontal passant par la source 104 et le point 106 de focalisation de la lumière émise par cette source 104 et réfléchie par le réflecteur 102. Conformément à l'invention ce point 106 de focalisation est situé en amont d'une lentille 108 de sortie - lentille torique - de telle sorte que le faisceau optique émis par la source 104 traverse la lentille 108 après s'être concentré en ce point 106 de focalisation.More specifically, Figures 1 and 2 represent views in vertical and horizontal sections respectively of such a module 100 at a reflector 102, these cuts being made in vertical and horizontal planes passing through the source 104 and the focusing point 106 of the light emitted by this source 104 and reflected by the reflector 102. In accordance with the invention this focusing point 106 is located upstream of an output lens 108 - toric lens - so that the optical beam emitted by the source 104 passes through the lens 108 after concentrating at this point of focusing.

Grâce à un tel point 106 de focalisation situé en amont de la lentille 108, il est possible de concentrer une part importante de la lumière émise par la source 104. A titre d'exemple, différents rayons 110, 112 et 114 émis par la source 104 sont représentés dans leur chemin optique allant de la source 104 jusqu'au large faisceau 101 en passant par le point 106 de focalisation.Thanks to such a focusing point 106 situated upstream of the lens 108, it is possible to concentrate a large part of the light emitted by the source 104. By way of example, different rays 110, 112 and 114 emitted by the source 104 are represented in their optical path from the source 104 to the broad beam 101 through the focusing point 106.

Cet agencement des éléments optiques est obtenu en considérant que la source 104 est située au niveau du premier foyer d'un ellipsoïde servant de base pour générer le réflecteur 102, le deuxième foyer de l'ellipsoïde étant placé au niveau du point 106 de focalisation.This arrangement of the optical elements is obtained by considering that the source 104 is located at the first focus of an ellipsoid serving as a base for generating the reflector 102, the second focus of the ellipsoid being placed at the point of focusing.

A partir d'un tel agencement pour un réflecteur et sa source associée, l'ensemble du module 100 est construit en faisant appel à une symétrie entre les différents réflecteurs. Dans cet exemple où le module comprend deux réflecteurs, cette symétrie est obtenue par rapport à un plan vertical 200 (Figure 2) passant par l'axe optique de la lentille torique 108, qui est constitué dans cet exemple de réalisation de l'intersection entre le plan vertical 200 avec un plan horizontal passant par la source 104. L'axe optique de la lentille torique 108 est par exemple matérialisé par l'axe Oy sur les Figures 3 et 4.From such an arrangement for a reflector and its associated source, the entire module 100 is constructed using a symmetry between the different reflectors. In this example where the module comprises two reflectors, this symmetry is obtained with respect to a vertical plane 200 ( Figure 2 ) passing through the optical axis of the toric lens 108, which is constituted in this embodiment of the intersection between the vertical plane 200 and a horizontal plane passing through the source 104. The optical axis of the toric lens 108 is for example materialized by the axis Oy on the Figures 3 and 4 .

Selon cette conception, les réflecteurs 102 et 102', les sources lumineuses 104 et 104' et les points de focalisation 106 et 106' sont symétriques par rapport au plan 200. De plus, comme on le voit sur la Figure 2, les segments 202 joignant la source 104 et le point 106, et 202' joignant la source 104' et le point 106' forment un angle a avec le plan médian 200.According to this design, the reflectors 102 and 102 ', the light sources 104 and 104' and the focusing points 106 and 106 'are symmetrical with respect to the plane 200. In addition, as can be seen in FIG. Figure 2 the segments 202 joining the source 104 and the point 106, and 202 'joining the source 104' and the point 106 'form an angle α with the median plane 200.

Il convient de noter que, sur la Figure 2 est représentée la ligne 118 des foyers de la lentille 108 qui comprend entre autres les points 106 et 106' de focalisation des réflecteurs 102 et 102'. La lentille 108 étant torique, les faisceaux 101 et 101' sont focalisés à l'infini dans le sens vertical, tandis que dans le sens horizontal ils subissent un étalement, pour leur permettre de remplir leur fonction d'éclairage.It should be noted that on the Figure 2 is shown the line 118 of the foci of the lens 108 which includes inter alia points 106 and 106 'of focusing reflectors 102 and 102'. The lens 108 being toric, the beams 101 and 101 'are focused at infinity in the vertical direction, while in the horizontal direction they undergo a spreading, to enable them to fulfill their lighting function.

Les réflecteurs 102 et 102' sont associés à une plaque plane 120 sensiblement horizontale comme représenté sur les Figures 3 et 4. Le plan de cette plaque 120 passe de préférence, mais pas nécessairement, sensiblement par les centres des sources lumineuses 104 et 104'. Les réflecteurs 102 et 102' sont situés au-dessus de la plaque 120 et la face supérieure de la plaque 120 est réfléchissante pour replier les faisceaux de rayons provenant des réflecteurs 102 et 102'.The reflectors 102 and 102 'are associated with a flat plate 120 that is substantially horizontal as represented on the Figures 3 and 4 . The plane of this plate 120 passes preferably, but not necessarily, substantially through the centers of the light sources 104 and 104 '. The reflectors 102 and 102 'are located above the plate 120 and the upper face of the plate 120 is reflective to fold the beam beams from the reflectors 102 and 102'.

La plaque 120 réfléchissante est appelée fréquemment "plieuse" et elle comporte un bord d'extrémité avant propre à former la coupure dans le faisceau d'éclairage, c'est-à-dire la limite supérieure au dessus de laquelle il n'y a pas de rayons lumineux. Lorsque la plaque 120 est horizontale, la coupure est horizontale et la zone éclairée par le faisceau provenant des réflecteurs 102 et 102' est située au-dessous d'une ligne horizontale.The reflective plate 120 is frequently called "bender" and has a front end edge adapted to form the cut in the light beam, that is to say the upper limit above which there is no light rays. When the plate 120 is horizontal, the cut is horizontal and the area illuminated by the beam from the reflectors 102 and 102 'is located below a horizontal line.

En référence aux Figures 3 et 4 sont représentées deux vues en perspective des réflecteurs 102 et 102' obtenus selon les agencements décrits ci-dessus à l'aide d'une réalisation utilisant un repère (O, x, y, z) où l'axe Oy est l'axe optique du module.With reference to Figures 3 and 4 are represented two perspective views of the reflectors 102 and 102 'obtained according to the arrangements described above with the aid of an embodiment using a reference (O, x, y, z) where the axis Oy is the optical axis of the module.

Dans un exemple numérique non limitatif, la lentille torique 108 a un rayon de courbure horizontal de 80mm et son centre a pour coordonnées (0, -30mm, 0). Le centre de la lentille torique 108 est défini par le centre de courbure dans le plan Oxy des faces d'entrée et de sortie de la lentille 108. Une telle lentille possède une ligne de foyers 118 confondue avec le bord de la plieuse (non représentée), la distance entre cette ligne 118 de foyers est la face d'entrée de la lentille 108 étant un tirage T de 28,8mm.In a non-limiting numerical example, the toric lens 108 has a horizontal radius of curvature of 80 mm and its center has coordinates (0, -30 mm, 0). The center of the toric lens 108 is defined by the center of curvature in the plane Oxy of the input and output faces of the lens 108. Such a lens has a line of foci 118 coincident with the edge of the folder (not shown) , the distance between this line 118 of foci is the entrance face of the lens 108 being a draw T 28.8mm.

A partir de ces paramètres et des coordonnées d'une source lumineuse (à savoir une diode électroluminescente située aux coordonnées (20mm; -14,715mm; - 0,376mm), les deux seconds foyers de chaque réflecteur sont déterminés de telle sorte que les collecteurs soient générés sur la base d'un ellipsoïde de révolution de focale F = 5,8 mm, la deuxième cavité étant générée par symétrie par rapport au plan 200 de symétrie (plan Oyz dans cet exemple).From these parameters and the coordinates of a light source (namely a light-emitting diode located at the coordinates (20mm, -14.715mm, 0.376mm), the two second focal points of each reflector are determined so that the collectors are generated on the basis of an ellipsoid of revolution focal length F = 5.8 mm, the second cavity being generated symmetrically with respect to plane 200 of symmetry (Oyz plane in this example).

Par la suite, des améliorations sont effectuées notamment, en considérant que la plieuse est l'extrusion simple de la ligne de foyers selon une direction opposée à la direction optique, des modifications secondaires étant effectuées sur les réflecteurs afin d'améliorer l'homogénéité de l'ensemble, pour obtenir le profil d'intensité représenté sur la Figure 6.Subsequently, improvements are made in particular, considering that the folder is the simple extrusion of the line of foci in a direction opposite to the optical direction, secondary modifications being made to the reflectors to improve the homogeneity of together, to obtain the intensity profile shown on the Figure 6 .

Il est également possible d'effectuer une correction de la plieuse pour améliorer le centre du faisceau. Plus précisément, la plieuse est extrudée (de 4mm suivant +y dans l'exemple des Figures 3 et 4) selon une forme qui suit les deux remontées de lumière au centre du faisceau. Cette forme plie les images au centre du faisceau au-dessus de la coupure qui viennent de l'association des deux points de focalisation des deux sources.It is also possible to perform a folder correction to improve the center of the beam. More precisely, the folder is extruded (from 4mm + y in the example of Figures 3 and 4 ) in a shape that follows the two ascents of light at the center of the beam. This shape folds the images in the center of the beam above the cut that come from the association of the two points of focus of the two sources.

La Figure 7 montre l'évolution au centre du faisceau tandis que la Figure 8 montre la répartition de la lumière à la surface de la plieuse, cette Figure mettant également en relief l'importance de la profondeur de la plieuse (32mm dans l'exemple précédent) afin de collecter le maximum de flux).The Figure 7 shows the evolution at the center of the beam while the Figure 8 shows the distribution of light on the surface of the folder, this figure also highlighting the importance of the depth of the folder (32mm in the previous example) to collect the maximum flow).

Cette Figure 8 montre en vue de dessus la concentration lumineuse projetée par les miroirs sur la plieuse (les axes sont gradués en millimètres horizontalement et verticalement). On voit en particulier que les maxima de lumière sont projetés sur le bord de la plieuse, mais on voit également qu'une quantité non négligeable de lumière parvient sur la plieuse en amont du bord.This Figure 8 shows a view from above of the light concentration projected by the mirrors on the folder (the axes are graduated in millimeters horizontally and vertically). We see in particular that the maximum light is projected on the edge of the folder, but we also see that a significant amount of light reaches the folder upstream of the edge.

On détermine ainsi la profondeur minimale pour envoyer plus de rayons lumineux sur la plieuse, de manière à les réfléchir vers la lentille, dans le but d'augmenter le flux lumineux du faisceau final 101. On peut donc optimiser cette profondeur en fonction du faisceau lumineux final désiré, c'est-à-dire en fonction de la réglementation à laquelle doit répondre ce faisceau lumineux.This determines the minimum depth to send more light rays on the folder, so as to reflect towards the lens, in order to increase the luminous flux of the final beam 101. We can therefore optimize this depth according to the desired final light beam, that is to say according to the regulations to which this light beam must respond.

Dans une dernière étape, on effectue une correction des réflecteurs et une amélioration de l'homogénéité en s'intéressant à l'extrémité et à la forme en V du faisceau.In a last step, reflectors are corrected and homogeneity is improved by focusing on the V-shaped end and shape of the beam.

Cette partie du faisceau résulte des bords des réflecteurs 102 et 102' (fig. 3) qui sont modifiés en choisissant une focale différente de la focale pour l'ellipsoïde ayant servi de base pour la réalisation des réflecteurs de manière à redresser la remontée de la lumière en focalisant légèrement avant le deuxième foyer du réflecteur.This part of the beam results from the edges of the reflectors 102 and 102 '( Fig. 3 ) which are modified by choosing a focal length different from the focal length for the ellipsoid used as a basis for the realization of the reflectors so as to straighten the rise of light by focusing slightly before the second focus of the reflector.

Par la suite est introduite une surface de raccord entre les deux sections du collecteur tout en assurant la continuité tangentielle sur toute la cavité, ce qui permet d'atteindre un flux représenté sur les Figures 9 et 10, qui présente un flux résultant de 276 lumen à partir de deux sources du type diode électroluminescente ayant une puissance optique de 250 lumen compte tenu de la glace extérieure qui représente, dans ce cas, 15% d'atténuation. On obtient ainsi un rendement final de 65% particulièrement satisfaisant.Subsequently is introduced a connecting surface between the two sections of the collector while ensuring tangential continuity over the entire cavity, which achieves a flow represented on the Figures 9 and 10 which has a resulting flux of 276 lumens from two light-emitting diode-type sources having an optical power of 250 lumen in view of the outer ice which in this case represents 15% attenuation. This gives a final yield of 65% particularly satisfactory.

La présente invention est susceptible de nombreuses variantes relatives au nombre de réflecteurs ou à la position d'un ou plusieurs éléments optiques d'un module. En résumé, la Figure 5 illustre les trois principales étapes décrites dans la réalisation d'un module conforme à l'invention, à savoir :

  • Une première étape de détermination de la ligne de foyers d'une lentille torique,
  • Une deuxième étape de détermination de la structure de base des réflecteurs sur la base d'un ellipsoïde dont les foyers correspondent, d'une part, à la source de faisceaux de lumière et, d'autre part, au point de focalisation de ces faisceaux,
  • Une troisième étape d'optimisation du faisceau global formé par la somme des différents faisceaux.
The present invention is capable of numerous variants relating to the number of reflectors or to the position of one or more optical elements of a module. In summary, the Figure 5 illustrates the three main steps described in the embodiment of a module according to the invention, namely:
  • A first step of determining the line of foci of a toric lens,
  • A second step of determining the basic structure of the reflectors on the basis of an ellipsoid whose foci correspond, on the one hand, to the source of light beams and, on the other hand, to the focal point of these beams ,
  • A third step of optimizing the overall beam formed by the sum of the different beams.

Claims (8)

Module (100) d'éclairage pour projecteur de véhicule automobile, apte à former un large faisceau lumineux (101) à coupure, muni d'éléments optiques comprenant une lentille de sortie (108) et une pluralité de réflecteurs (102, 102') concaves associés à une plieuse présentant une face réfléchissante destinée à replier des faisceaux lumineux (110, 112, 114, 116) générés par des sources lumineuses (104, 104') situées dans les concavités des réflecteurs (102, 102'), la lentille de sortie (108) étant torique, et ces éléments optiques étant agencés de manière à faire converger les faisceaux lumineux (110, 112, 114, 116) générés par lesdites sources lumineuses (104, 104') en des points de focalisation (106, 106') préalablement à la transmission de ces faisceaux lumineux par la lentille de sortie (108),
caractérisé en ce qu'il comprend deux réflecteurs (102, 102') orientés l'un vers l'autre.Motor vehicle headlight lighting module (100), capable of forming a wide cut-off light beam (101), provided with optical elements comprising an exit lens (108) and a plurality of reflectors (102, 102 ') concave associated with a folder having a reflective face for folding light beams (110, 112, 114, 116) generated by light sources (104, 104 ') located in the concavities of the reflectors (102, 102'), the lens an output (108) being a toric, and these optical elements being arranged to converge the light beams (110, 112, 114, 116) generated by said light sources (104, 104 ') at focusing points (106, 106 ') prior to transmission of these light beams through the exit lens (108),
characterized in that it comprises two reflectors (102, 102 ') oriented toward each other. Module d'éclairage (100) selon la revendication 1 caractérisé en ce que les points de focalisation (106, 106') sont situés sur une ligne (118) de foyers de la lentille (108).Lighting module (100) according to claim 1 characterized in that the focusing points (106, 106 ') are located on a line (118) of focal points of the lens (108). Module d'éclairage (100) selon l'une des revendications 1 ou 2, caractérisé en ce que la plieuse suit, partiellement ou totalement, la ligne de foyers (118) de la lentille (108).Lighting module (100) according to one of claims 1 or 2, characterized in that the folder follows, partially or completely, the line of foci (118) of the lens (108). Module d'éclairage (100) selon l'une des revendications 1 à 3, caractérisé en ce que les réflecteurs (102, 102') sont basés sur une forme d'ellipsoïde présentant deux foyers, la source lumineuse (104, 104') d'un réflecteur étant située dans un premier foyer de cet ellipsoïde et le point de focalisation (106, 106') étant situé dans un second foyer de cet même ellipsoïde.Lighting module (100) according to one of claims 1 to 3, characterized in that the reflectors (102, 102 ') are based on an ellipsoid shape having two foci, the light source (104, 104') a reflector being located in a first focus of this ellipsoid and the focusing point (106, 106 ') being located in a second focus of the same ellipsoid. Module d'éclairage (100) selon la revendication 4 caractérisé en ce que l'axe (202, 202') d'un réflecteur (102, 102'), passant par le premier et le second foyer de l'ellipsoïde à sa base, forme un angle non nul avec l'axe optique (Oy) de la lentille (108).Lighting module (100) according to claim 4 characterized in that the axis (202, 202 ') of a reflector (102, 102'), passing through the first and second focus of the ellipsoid at its base , forms a non-zero angle with the optical axis (Oy) of the lens (108). Module d'éclairage (100) selon l'une des revendications précédentes caractérisé en ce qu'il présente un plan de symétrie (200).Lighting module (100) according to one of the preceding claims characterized in that it has a plane of symmetry (200). Module d'éclairage selon l'une des revendications précédentes caractérisé en ce que l'ouverture latérale totale du faisceau optique est comprise entre 40 degrés et 100 degrés.Lighting module according to one of the preceding claims, characterized in that the total lateral opening of the optical beam is between 40 degrees and 100 degrees. Procédé de fabrication d'un module d'éclairage (100) pour projecteur de véhicule automobile, apte à former un large faisceau lumineux (101) à coupure, muni d'éléments optiques comprenant une lentille (108) de sortie et une pluralité de réflecteurs (102, 102') concaves associés à une plieuse présentant une face réfléchissante destinée à replier des faisceaux lumineux (110, 112, 114, 116) générés par des sources lumineuses (104, 104') situées dans les concavités des réflecteurs (102, 102'), caractérisé en ce qu'il comprend l'étape d'agencer ces éléments optiques de manière à faire converger les faisceaux lumineux (110, 112, 114, 116) générés par lesdites sources lumineuses (104, 104') en des points de focalisation (106, 106') préalablement à la transmission de ces faisceaux lumineux par la lentille de sortie conformément à un module selon l'une des revendications précédentes.A method of manufacturing a lighting module (100) for a motor vehicle headlamp, capable of forming a broad light beam (101) with cutoff, provided with optical elements comprising an output lens (108) and a plurality of reflectors Concave (102, 102 ') associated with a folder having a reflecting surface for folding light beams (110, 112, 114, 116) generated by light sources (104, 104') in the concavities of the reflectors (102, 102 '), characterized in that it comprises the step of arranging these optical elements so as to converge the light beams (110, 112, 114, 116) generated by said light sources (104, 104') into focusing points (106, 106 ') prior to the transmission of these light beams by the output lens according to a module according to one of the preceding claims.
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