EP3270043B1 - Multi-component reflector for light module of a motor vehicle headlight - Google Patents

Multi-component reflector for light module of a motor vehicle headlight Download PDF

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Publication number
EP3270043B1
EP3270043B1 EP17175679.4A EP17175679A EP3270043B1 EP 3270043 B1 EP3270043 B1 EP 3270043B1 EP 17175679 A EP17175679 A EP 17175679A EP 3270043 B1 EP3270043 B1 EP 3270043B1
Authority
EP
European Patent Office
Prior art keywords
shell
light module
light
circuit board
reflector
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.)
Active
Application number
EP17175679.4A
Other languages
German (de)
French (fr)
Other versions
EP3270043A1 (en
EP3270043B9 (en
Inventor
Andreas Maier
Stephan Braun
Carsten Otto
Ernst-Olaf Rosenhahn
Robert Leute
Martin Biedermann
Ephraim Singer
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.)
Marelli Automotive Lighting Reutlingen Germany GmbH
Original Assignee
Automotive Lighting Reutlingen GmbH
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Automotive Lighting Reutlingen GmbH filed Critical Automotive Lighting Reutlingen GmbH
Publication of EP3270043A1 publication Critical patent/EP3270043A1/en
Application granted granted Critical
Publication of EP3270043B1 publication Critical patent/EP3270043B1/en
Publication of EP3270043B9 publication Critical patent/EP3270043B9/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
    • F21S45/00—Arrangements within vehicle lighting devices specially adapted for vehicle exteriors, for purposes other than emission or distribution of light
    • F21S45/40—Cooling of lighting devices
    • F21S45/47—Passive cooling, e.g. using fins, thermal conductive elements or openings
    • 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
    • F21S41/16—Laser light sources
    • 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
    • F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/19—Attachment of light sources or lamp holders
    • 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
    • F21S41/19—Attachment of light sources or lamp holders
    • F21S41/192—Details of lamp holders, terminals or connectors
    • 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
    • F21S41/37—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by reflectors characterised by their material, surface treatment or coatings
    • 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
    • F21S41/39—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
    • F21S45/00—Arrangements within vehicle lighting devices specially adapted for vehicle exteriors, for purposes other than emission or distribution of light
    • F21S45/40—Cooling of lighting devices
    • F21S45/47—Passive cooling, e.g. using fins, thermal conductive elements or openings
    • F21S45/48—Passive cooling, e.g. using fins, thermal conductive elements or openings with means for conducting heat from the inside to the outside of the lighting devices, e.g. with fins on the outer surface of the lighting device

Definitions

  • the present invention relates to a light module of a motor vehicle headlight according to the preamble of claim 1.
  • a light module is from US Pat EP 2 589 479 A2 known.
  • a metallic reflector shell is coated with a plastic material to form a reflector surface, which is preferably done by spraying plastic onto the reflector shell.
  • reflectors are usually made of plastics such as thermoset, thermoplastic or metallic materials such as. E.g. aluminum produced. These materials are usually surface treated to meet optical requirements.
  • the surface accuracy to be achieved depends heavily on the type of surface treatment, which must be taken into account when designing the light module.
  • Expensive manufacturing equipment e.g. painting systems
  • Process windows must be provided, and compliance with them must be monitored in order to record and limit fluctuations in quality.
  • E.g. sink marks that occur due to shrinkage when a cast reflector cools, inaccuracies due to geometric distortions, burr formation, etc.
  • the stiffness of the reflectors to be achieved varies greatly depending on the material and has led to considerable problems in the past.
  • the required quality of the optical surface to be achieved in turn, severely limits the possibilities of mechanical stabilization of the reflectors.
  • one or more additional elements are usually required to dissipate the thermal energy that has accrued and / or for mechanical fastening. Due to the transmission technology, deterioration in efficiency must be accepted for heat dissipation. Additional costs by increasing the use of materials are necessary.
  • the object of the invention is to provide a light module which does not have these disadvantages or at least has only to a greatly reduced extent.
  • the light module according to the invention is characterized in that the support shell and the reflection shell are shaped and dimensioned to match each other so that a convex rear side of the reflection shell facing away from its light exit side is received by a concave surface of the support shell with a precise fit, free of play and with a slight bias.
  • the light module according to the invention has an optimized degree of efficiency and is also characterized by a reduced space requirement.
  • the efficiency is understood to mean the luminous flux standardized to the luminous flux of the light sources, which is emitted by the light module into the solid angle of a light distribution that conforms to the rules for motor vehicles.
  • the modular structure allows a combination of several positive properties of the individual materials in order to create an effective, cost-effective component with high dimensional accuracy which delivers the required surface quality without expensive and time-consuming (quality-reducing) subsequent processes.
  • the modular structure has the advantage of reducing the tolerance chain within the lighting system of the light module. Another advantage is the possibility of a Reduction of the total weight of the light module.
  • the elimination of process steps in the manufacturing process, which are required in the case of one-piece reflectors to achieve the required surface accuracy, results in a reduction in capital commitment in production by eliminating machine systems.
  • the possible lower use of material allows a reduction in the space required for installation in the headlight.
  • the semiconductor light source has at least one light-emitting diode or laser diode or an array of light-emitting diodes or laser diodes.
  • the base material of the first material is a light metal such as aluminum or magnesium or an alloy containing at least one of these light metals.
  • Another preferred embodiment is characterized in that the second material is a plastic.
  • the support shell of the reflector in the light module is fastened to a swivel frame of the light module with a suitable fastening means, preferably with a screw.
  • the reflection shell is clamped between the circuit board and the support shell and thus fastened.
  • Another preferred embodiment is characterized in that the surface-enlarging structures have the shape of ribs in order to be able to give off heat to the environment.
  • reflection shell and the board have mutually complementary and interlocking positioning structures.
  • the positioning structures are projections in the reflective shell that engage without play in corresponding, i.e. suitably dimensioned, recesses in the board, or that the positioning structures are projections on the board that engage without play with recesses of the reflective shell that are dimensioned to match.
  • Another preferred embodiment is characterized in that similar or identical positioning structures are also arranged on or in the board on its side facing the support shell and in or on the support shell and are dimensioned so that they interlock without play.
  • the support shell has projections protruding into the clear width of the opening of the end on the light exit side at its end on the light exit side.
  • the support shell has at least two such projections, one of which projects into said opening from the right side and one from the left side and forms a stop in the sideways direction and a stop in the light exit direction perpendicular to the sideways direction.
  • Figures 1 and 2 a swivel frame 1 of a motor vehicle headlight, which is part of an exemplary embodiment of a light module 10 according to the invention.
  • the Figure 1 shows a perspective view of a rear side of the swivel frame 1 and the light module 10, while the Figure 2 shows a perspective view of the front of the swivel frame 1 and the light module 10.
  • the pivot frame 1 has a barrel-shaped bearing journal 2, a spherical bearing journal 3 and a receptacle 4 for a spherical bearing journal.
  • the bearing pins 2, 3 and the receptacle 4 form articulation structures with which the swivel frame is pivotably mounted in a housing of the motor vehicle headlight when it is used as intended in a motor vehicle headlight.
  • the barrel-shaped bearing journal 2, together with the spherical bearing journal 3, defines a pivot axis for a headlight range control and the spherical bearing journal 38, together with the receptacle 40, defines a pivot axis for a cornering light function.
  • the pins 2, 3 and the receptacle 4 are not essential for the invention and are only mentioned here for a better understanding of the embodiment shown.
  • the x-direction When used as intended, the x-direction will be approximately parallel to the longitudinal axis of the vehicle, while the y-direction will be approximately parallel to the transverse vehicle axis and the z-direction will be approximately parallel to the vertical axis of the vehicle.
  • the light module 10 has a support shell 12, a reflection shell 14 and a circuit board 16 and, in the embodiment shown, is rigidly connected to the swivel frame 1 by a suitable connection.
  • the suitable connection is preferably a screw connection or a rivet connection.
  • Figure 2 shows the subject of Figure 1 obliquely from the front, so that a reflective surface 18 of the reflective shell 14 can be seen.
  • the reflection shell 14 has two reflector chambers, but this is not essential for the invention.
  • a reflector of a light module 10 according to the invention can also have only one or more than two reflector chambers.
  • each semiconductor light source 20 has at least one light-emitting diode or laser diode or an array of light-emitting diodes or laser diodes.
  • Screws 22 open to the front are used, for example, to screw a screen unit and / or a lens holder unit onto the swivel frame 1 of the light module 10.
  • a screen unit is used in particular to generate a cut-off line for a low-beam light distribution.
  • the light module according to the invention would be a component of a so-called projection light module, which images a diaphragm edge of the said diaphragm as a sharp cut-off line.
  • the light module can also be a direct be an imaging light module in which the reflector generates the light distribution directly from the light from the light sources, without the need for a further optical element in the form of a lens or a further reflector in the bundle of the light emanating from the reflective surface.
  • the closed screw ends 24 visible in the upper half of the swivel frame 1 serve to hold screws with which the support shell 12 is screwed to the swivel frame 1.
  • the closed screw ends 25 visible in the lower half of the swivel frame 1 serve to hold screws with which a further light module, for example a high beam module, is fastened to the swivel frame 1 with a second reflector.
  • FIGS. 3 to 5 show vertical cuts or, in the case of the Figure 5 part of a vertical section through the subject matter of Figures 1 and 2 .
  • the Figure 3 a cut that is in the Figure 1 lies in the y-direction approximately in the middle of the light module 10 and parallel to the xz-plane and in particular shows an attachment of the support shell 12 to the swivel frame 1.
  • Figure 3 shows in particular a support shell 12 with reflection shell 14 and the circuit board 16 with a semiconductor light source 20.
  • the semiconductor light source 20 is a light-emitting diode, an array of several light-emitting diodes, a laser diode, or an array of several laser diodes.
  • the support shell 12 consists of a first material, and a reflection shell 14 resting against the support shell 12 consists of a second material.
  • the support shell 12 and the reflection shell 14 together form a reflector with a reflection surface 18.
  • the base material of the first material is preferably a light metal such as aluminum or magnesium or an alloy containing at least one of these light metals.
  • a base material is characterized by good mechanical strength and good thermal conductivity. Its surface forms a thermally effective, i.e. heat-absorbing surface of the reflector or light module 10 that emits heat to the environment. The selection of this base material of the thermally effective surface increases the effectiveness of the overall system, under which the effectiveness of heat dissipation is increased the light sources and the circuit board is meant.
  • the second material is, for example, a plastic.
  • This plastic then forms the base material of the optically effective reflection surface 18.
  • the selection of this base material makes subsequent processes, such as painting, unnecessary. All in all, the division of the component functions into different materials allows the avoidance of system-related disadvantages of a reflector consisting of only one material, which in the prior art must fulfill both the mechanical, thermal and optical functions.
  • a plug element 26 arranged on the circuit board 16 is used for making electrical contact and for supplying energy to the semiconductor light source 20.
  • a screw 28 is the The support shell 12 of the reflector is fastened in the light module 10, for example on a swivel frame 1 of the light module 10.
  • Figure 4 shows a cross-section through the light module 10 according to the invention, which runs parallel to the xz plane and which is approximately at the level of a fastening screw or a screw dome 32 that receives this screw, with which the board 16 is connected to the reflection shell 14 and the support shell 12 .
  • Figure 2 shows Figure 2
  • a screw resistor 32 as part of the support shell 12 and a recess 34 in the board 16.
  • the support shell 12 preferably has surface-enlarging structures 36 on its rear side facing away from the reflection shell 14. These surface-enlarging structures 36 preferably have the shape of ribs in order to be able to give off heat to the surroundings. The ribs preferably run parallel to the xz plane. With this arrangement, better heat dissipation from the light-emitting diode is achieved. Compared to the alternative of pin-shaped cooling structures, this form offers the The advantage of also having an additional stiffening effect, which makes it possible to use lightweight support shells 12 with comparatively little use of material.
  • the support shell 12 has fastening elements 38 for fastening the circuit board 16.
  • the fastening elements 38 are screw ends 32.
  • Figure 5 shows a cross section through a light module 10 according to the invention, parallel to the xz plane and in the vicinity of a lateral edge of the light module 10 in the y direction
  • Figure 5 is the side edge of the in Figure 1 left edge of the light module 10.
  • the reflection shell 14 and the board 16 have mutually complementary and interlocking positioning structures 38, 40, which are from the plane of the section Figure 5 get cut.
  • the positioning structures 38, 40 fix the circuit board 16 and in particular a semiconductor light source 20 arranged on the circuit board 16 with an accuracy defined by the manufacturing accuracy of the positioning structures 38, 40 relative to the reflector 12 consisting of the support shell 12 and reflection shell 14.
  • the positioning structures are preferably projections 38 in the reflection shell 14, which engage in corresponding, ie suitably dimensioned, recesses 40 of the circuit board 16 without play.
  • the Positioning structures can also be projections on the circuit board 16, which engage in recesses of the reflective shell 14 that are dimensioned to match, without play.
  • Similar or identical positioning structures are preferably also or in the circuit board 20 on its side facing the support shell 12 and in or on the support shell 12. These also interlock without play in such a way that the position of the support shell 12 in relation to the printed circuit board 16 and thus in relation to the light source (s) 20 is determined with high precision.
  • Such positioning structures are preferably also in the vicinity of the Figure 1 arranged on the left edge of the light module.
  • Figure 2 shows that the support shell 12 has projections 44 protruding into the clear width of the opening of the end on the light exit side at its end on the light exit side.
  • each of these projections 44 each form a stop for an edge of the reflection shell 14 on the light exit side.
  • the support shell preferably has at least two such projections 44, one from the right side and one from the left side protrudes into said opening and forms a stop in the sideways direction (y-direction and opposite direction) and a stop in the light exit direction (x-direction).
  • the support shell 12 and the reflection shell 14 are shaped and dimensioned to match one another in the sense that a convex side facing away from their light exit side
  • the back of the reflective shell 14 is a precise fit, free of play and with a slight bias, taken up by a concave surface of the support shell.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)
  • Lighting Device Outwards From Vehicle And Optical Signal (AREA)

Description

Die vorliegende Erfindung betrifft ein Lichtmodul eines Kraftfahrzeugscheinwerfers nach dem Oberbegriff des Anspruchs 1. Ein solches Lichtmodul ist aus der EP 2 589 479 A2 bekannt. Bei dem bekannten Lichtmodul wird eine metallische Reflektorschale zur Bildung einer Reflektorfläche mit einem Kunststoffmaterial ummantelt, was vorzugsweise durch Aufspritzen von Kunststoff auf die Reflektorschale erfolgt.The present invention relates to a light module of a motor vehicle headlight according to the preamble of claim 1. Such a light module is from US Pat EP 2 589 479 A2 known. In the known light module, a metallic reflector shell is coated with a plastic material to form a reflector surface, which is preferably done by spraying plastic onto the reflector shell.

Reflektoren werden heute üblicherweise aus Kunststoffen wie Duroplast, Thermoplast oder aus metallischen Werkstoffen wie z. Bsp. Aluminium hergestellt. Diese Materialien werden in der Regel oberflächenbehandelt um optische Anforderungen zu erfüllen.Today, reflectors are usually made of plastics such as thermoset, thermoplastic or metallic materials such as. E.g. aluminum produced. These materials are usually surface treated to meet optical requirements.

Die zu erreichende Oberflächengenauigkeit ist stark von der Art der Oberflächenbehandlung abhängig, was bereits beim Entwurf des Lichtmoduls berücksichtigt werden muss. Derzeit sind teure Fertigungsmittel (z. Bsp. Lackieranlagen) notwendig um die Reflektor-Rohteile für die finale Oberflächenbehandlung aufzubereiten. Dabei müssen Prozessfenster vorgesehen werden, und deren Einhaltung muss überwacht werden, um Schwankungen der Qualität zu erfassen und einzuschränken. Je nach verwendetem Werkstoff bestehen Einschränkungen in der Gestaltung der Bauteile (durch die zur Herstellung notwendige Werkzeugtechnologie) wie z. Bsp. Einfallstellen, die durch Schrumpfung beim Abkühlen eines gegossenen Reflektors auftreten, Ungenauigkeiten durch geometrische Verzüge, Gratbildung etc.The surface accuracy to be achieved depends heavily on the type of surface treatment, which must be taken into account when designing the light module. Expensive manufacturing equipment (e.g. painting systems) is currently required to prepare the reflector raw parts for the final surface treatment. Process windows must be provided, and compliance with them must be monitored in order to record and limit fluctuations in quality. Depending on the material used, there are restrictions in the design of the components (due to the tool technology required for production) such as E.g. sink marks that occur due to shrinkage when a cast reflector cools, inaccuracies due to geometric distortions, burr formation, etc.

Durch die bauteileigenen und baugruppenabhängigen Toleranzen sind beim Entwurf Wirkungsgradverluste des Gesamtsystems zu berücksichtigen, was Kosten und Aufwand erhöht.Due to the component-specific and component-dependent tolerances, losses in efficiency of the overall system must be taken into account in the design, which increases costs and effort.

Die zu erreichende Steifigkeit der Reflektoren ist je nach Werkstoff stark unterschiedlich und hat in der Vergangenheit zu erheblichen Problemen geführt. Die geforderte Güte der zu erreichenden optischen Fläche schränkt wiederum die Möglichkeiten der mechanischen Stabilisierung der Reflektoren stark ein.The stiffness of the reflectors to be achieved varies greatly depending on the material and has led to considerable problems in the past. The required quality of the optical surface to be achieved, in turn, severely limits the possibilities of mechanical stabilization of the reflectors.

Zusätzlich sind in der Regel ein oder mehrere weitere Elemente zur Abführung der angefallenen Wärmeenergie und oder zur mechanischen Befestigung notwendig. Zur Wärmeabfuhr sind bedingt durch die Übertragungstechnologie Wirkungsgradverschlechterungen hinzunehmen. Mehrkosten durch Erhöhung des Materialeinsatzes sind notwendig.In addition, one or more additional elements are usually required to dissipate the thermal energy that has accrued and / or for mechanical fastening. Due to the transmission technology, deterioration in efficiency must be accepted for heat dissipation. Additional costs by increasing the use of materials are necessary.

Vor diesem Hintergrund besteht die Aufgabe der Erfindung in der Angabe eines Lichtmoduls, das diese Nachteile nicht oder zumindest allenfalls nur in einem stark verringerten Umfang aufweist.Against this background, the object of the invention is to provide a light module which does not have these disadvantages or at least has only to a greatly reduced extent.

Diese Aufgabe wird mit den Merkmalen des Anspruchs 1 gelöst. Das erfindungsgemäße Lichtmodul zeichnet sich dadurch aus, dass die Stützschale und die Reflexionsschale so zueinander passend geformt und dimensioniert sind, dass eine konvexe, ihrer Lichtaustrittsseite abgewandte Rückseite der Reflexionsschale passgenau, spielfrei und unter leichter Vorspannung durch eine konkave Fläche der Stützschale aufgenommen wird.This object is achieved with the features of claim 1. The light module according to the invention is characterized in that the support shell and the reflection shell are shaped and dimensioned to match each other so that a convex rear side of the reflection shell facing away from its light exit side is received by a concave surface of the support shell with a precise fit, free of play and with a slight bias.

Durch diese Merkmale wird ein gleichzeitig sehr präzises und mechanisch belastbares Lichtmodul mit im Vergleich zum Stand der Technik verringertem Materialeinsatz bereitgestellt. Das erfindungsgemäße Lichtmodul weist einen optimierten Wirkungsgrad auf und zeichnet sich ferner durch eine reduzierte Bauraumforderung aus. Unter dem Wirkungsgrad wird dabei der auf den Lichtstrom der Lichtquellen normierte Lichtstrom verstanden, der von dem Lichtmodul in den Raumwinkel einer für Kraftfahrzeuge regelkonformen Lichtverteilung abgestrahlt wird.These features provide a light module that is very precise and mechanically resilient at the same time and that uses less material compared to the prior art. The light module according to the invention has an optimized degree of efficiency and is also characterized by a reduced space requirement. The efficiency is understood to mean the luminous flux standardized to the luminous flux of the light sources, which is emitted by the light module into the solid angle of a light distribution that conforms to the rules for motor vehicles.

Für jede Komponente des Lichtmoduls erlaubt der modulare Aufbau eine Kombination mehrerer positiver Eigenschaften der Einzelwerkstoffe um ein effektives, kostengünstiges Bauteil mit hoher Formgenauigkeit zu schaffen welches ohne teure und aufwändige (qualitätsmindernde) Folgeprozesse die geforderte Oberflächenqualität liefert. Der modulare Aufbau führt zu dem Vorteil eine Reduzierung der Toleranzkette innerhalb des lichttechnischen Systems des Lichtmoduls. Als weiterer Vorteil ergibt sich die Möglichkeit einer Reduzierung des Gesamtgewichts des Lichtmoduls. Durch den Entfall von Prozessschritten im Fertigungsprozess, die bei einteiligen Reflektoren zur Erzielung der geforderten Oberflächengenauigkeit erforderlich sind, ergibt sich in der Fertigung eine Reduzierung von Kapitalbindung durch den Entfall von Maschinenanlagen. Der mögliche geringere Materialeinsatz erlaubt eine Verringerung des für den Einbau erforderlichen Bauraums im Scheinwerfer.For each component of the light module, the modular structure allows a combination of several positive properties of the individual materials in order to create an effective, cost-effective component with high dimensional accuracy which delivers the required surface quality without expensive and time-consuming (quality-reducing) subsequent processes. The modular structure has the advantage of reducing the tolerance chain within the lighting system of the light module. Another advantage is the possibility of a Reduction of the total weight of the light module. The elimination of process steps in the manufacturing process, which are required in the case of one-piece reflectors to achieve the required surface accuracy, results in a reduction in capital commitment in production by eliminating machine systems. The possible lower use of material allows a reduction in the space required for installation in the headlight.

Bevorzugt ist auch, dass die Halbleiterlichtquelle wenigstens eine Leuchtdiode oder Laserdiode oder ein Feld von Leuchtdioden oder Laserdioden aufweist.It is also preferred that the semiconductor light source has at least one light-emitting diode or laser diode or an array of light-emitting diodes or laser diodes.

Ferner ist bevorzugt, dass der Grundwerkstoff des ersten Materials ein Leichtmetall wie Aluminium oder Magnesium oder eine wenigstens eines dieser Leichtmetalle enthaltende Legierung ist.It is also preferred that the base material of the first material is a light metal such as aluminum or magnesium or an alloy containing at least one of these light metals.

Eine weitere bevorzugte Ausgestaltung zeichnet sich dadurch aus, dass das zweite Material ein Kunststoff ist.Another preferred embodiment is characterized in that the second material is a plastic.

Bevorzugt ist auch, dass die Stützschale des Reflektors im Lichtmodul mit einem geeigneten Befestigungsmittel, bevorzugt mit einer Schraube, an einem Schwenkrahmen des Lichtmoduls befestigt ist.It is also preferred that the support shell of the reflector in the light module is fastened to a swivel frame of the light module with a suitable fastening means, preferably with a screw.

Ferner ist bevorzugt, dass die Reflexionsschale zwischen der Platine und der Stützschale eingeklemmt und damit befestigt ist.It is also preferred that the reflection shell is clamped between the circuit board and the support shell and thus fastened.

Eine weitere bevorzugte Ausgestaltung zeichnet sich dadurch aus, dass die oberflächenvergrößernden Strukturen eine Form von Rippen besitzen, um Wärme an die Umgebung abgeben zu können.Another preferred embodiment is characterized in that the surface-enlarging structures have the shape of ribs in order to be able to give off heat to the environment.

Bevorzugt ist auch, dass die Reflexionsschale und die Platine zueinander komplementäre und ineinandergreifende Positionierungsstrukturen aufweisen.It is also preferred that the reflection shell and the board have mutually complementary and interlocking positioning structures.

Ferner ist bevorzugt, dass die Positionierungsstrukturen Vorsprünge in der Reflexionsschale sind, die spielfrei in dazu korrespondierende, d.h. passend dimensionierte Ausnehmungen der Platine greifen, oder dass die Positionierungsstrukturen Vorsprünge auf der Platine sind, die spielfrei in dazu passend dimensionierte Ausnehmungen der Reflexionsschale greifen.Furthermore, it is preferred that the positioning structures are projections in the reflective shell that engage without play in corresponding, i.e. suitably dimensioned, recesses in the board, or that the positioning structures are projections on the board that engage without play with recesses of the reflective shell that are dimensioned to match.

Eine weitere bevorzugte Ausgestaltung zeichnet sich dadurch aus, dass ähnliche oder gleiche Positionierungsstrukturen auch auf, beziehungsweise in der Platine auf deren der Stützschale zugewandten Seite und in, beziehungsweise an der Stützschale angeordnet sind und so dimensioniert sind, dass sie spielfrei ineinander greifen.Another preferred embodiment is characterized in that similar or identical positioning structures are also arranged on or in the board on its side facing the support shell and in or on the support shell and are dimensioned so that they interlock without play.

Bevorzugt ist auch, dass die Stützschale an ihrem lichtaustrittsseitigen Ende in die lichte Weite der Öffnung des lichtaustrittseitigen Endes hineinragende Vorsprünge aufweist.It is also preferred that the support shell has projections protruding into the clear width of the opening of the end on the light exit side at its end on the light exit side.

Ferner ist bevorzugt, dass die Stützschale wenigstens zwei solche Vorsprünge aufweist, von denen jeweils einer von der rechten Seite und einer von der linken Seite in die genannte Öffnung hineinragt und einen Anschlag in der Seitwärtsrichtung und einen Anschlag in der zur Seitwärtsrichtung senkrechten Lichtaustrittsrichtung bildet.It is also preferred that the support shell has at least two such projections, one of which projects into said opening from the right side and one from the left side and forms a stop in the sideways direction and a stop in the light exit direction perpendicular to the sideways direction.

Weitere Vorteile ergeben sich aus den abhängigen Ansprüchen, der Beschreibung und den beigefügten Figuren.Further advantages emerge from the dependent claims, the description and the attached figures.

Es versteht sich, dass die vorstehend genannten und die nachstehend noch zu erläuternden Merkmale nicht nur in der jeweils angegebenen Kombination, sondern auch in anderen Kombinationen oder in Alleinstellung verwendbar sind, ohne den Rahmen der vorliegenden Erfindung, die nur durch die beigelegte Ansprüche limitiert wird, zu verlassen.It goes without saying that the features mentioned above and those yet to be explained below can be used not only in the respectively specified combination, but also in other combinations or on their own, without the scope of the present invention, which is only limited by the appended claims, to leave.

Ausführungsbeispiele der Erfindung sind in den Zeichnungen dargestellt und werden in der nachfolgenden Beschreibung näher erläutert. Dabei bezeichnen gleiche Bezugszeichen in verschiedenen Figuren jeweils gleiche oder zumindest ihrer Funktion nach vergleichbare Elemente. Es zeigen, jeweils in schematischer Form:

Figur 1
einen Schwenkrahmen eines Kraftfahrzeugscheinwerfers mit einem erfindungsgemäßen Lichtmodul von schräg hinten;
Figur 2
den Gegenstand der Figur 1 von schräg vorne;
Figur 3
einen in der Mitte des Lichtmoduls parallel zur Hauptabstrahlrichtung liegenden vertikalen Querschnitt, der insbesondere eine Befestigung des Lichtmoduls an einem Schwenkrahmen zeigt;
Figur 4
einen dazu parallel liegenden Querschnitt durch das Lichtmodul, der in der Höhe einer Befestigungsschraube liegt, mit der die Platine mit der Reflektorschale und der Stützschale verbunden ist; und
Figur 5
einen in der Nähe zweiten seitlichen Randes des Lichtmoduls liegenden Querschnitts des Lichtmoduls.
Exemplary embodiments of the invention are shown in the drawings and are explained in more detail in the following description. The same reference symbols in different figures denote the same or at least comparable elements in terms of their function. They show, each in schematic form:
Figure 1
a swivel frame of a motor vehicle headlight with a light module according to the invention obliquely from behind;
Figure 2
the subject of Figure 1 from diagonally in front;
Figure 3
a vertical cross section lying in the middle of the light module parallel to the main emission direction, which shows in particular an attachment of the light module to a swivel frame;
Figure 4
a parallel cross-section through the light module, which is at the level of a fastening screw with which the circuit board is connected to the reflector shell and the support shell; and
Figure 5
a cross-section of the light module located in the vicinity of the second lateral edge of the light module.

Im Einzelnen zeigen die Figuren 1 und 2 einen Schwenkrahmen 1 eines Kraftfahrzeugscheinwerfers, der ein Bestandteil eines Ausführungsbeispiels eines erfindungsgemäßen Lichtmoduls 10 ist. Die Figur 1 zeigt dabei eine perspektivische Ansicht einer Rückseite des Schwenkrahmens 1 und des Lichtmoduls 10, während die Figur 2 eine perspektivische Ansicht der Vorderseite des Schwenkrahmens 1 und des Lichtmoduls 10 zeigt.In detail, they show Figures 1 and 2 a swivel frame 1 of a motor vehicle headlight, which is part of an exemplary embodiment of a light module 10 according to the invention. The Figure 1 shows a perspective view of a rear side of the swivel frame 1 and the light module 10, while the Figure 2 shows a perspective view of the front of the swivel frame 1 and the light module 10.

Der Schwenkrahmen 1 weist in dem dargestellten Ausführungsbeispiel einen tonnenförmigen Lagerzapfen 2, einen kugelförmigen Lagerzapfen 3 und eine Aufnahme 4 für einen kugelförmigen Lagerzapfen auf. Die Lagerzapfen 2, 3 und die Aufnahme 4 bilden Anlenkstrukturen, mit denen der Schwenkrahmen bei seiner bestimmungsgemäßen Verwendung in einem Kraftfahrzeugscheinwerfer schwenkbar in einem Gehäuse des Kraftfahrzeugscheinwerfers gelagert ist. Der tonnenförmige Lagerzapfen 2 definiert zusammen mit dem kugelförmigen Lagerzapfen 3 eine Schwenkachse für eine Leuchtweitenregelung und der kugelförmige Lagerzapfen 38 definiert zusammen mit der Aufnahme 40 eine Schwenkachse für eine Kurvenlichtfunktion. Die Zapfen 2, 3 und die Aufnahme 4 sind für die Erfindung nicht wesentlich und werden hier lediglich zum besseren Verständnis der dargestellten Ausgestaltung erwähnt.In the exemplary embodiment shown, the pivot frame 1 has a barrel-shaped bearing journal 2, a spherical bearing journal 3 and a receptacle 4 for a spherical bearing journal. The bearing pins 2, 3 and the receptacle 4 form articulation structures with which the swivel frame is pivotably mounted in a housing of the motor vehicle headlight when it is used as intended in a motor vehicle headlight. The barrel-shaped bearing journal 2, together with the spherical bearing journal 3, defines a pivot axis for a headlight range control and the spherical bearing journal 38, together with the receptacle 40, defines a pivot axis for a cornering light function. The pins 2, 3 and the receptacle 4 are not essential for the invention and are only mentioned here for a better understanding of the embodiment shown.

Bei der bestimmungsgemäßen Verwendung wird die x-Richtung etwa parallel zur Fahrzeuglängsachse liegen, während die y-Richtung etwa parallel zur Fahrzeugquerachse und die z-Richtung etwa parallel zur Fahrzeughochachse liegen wird.When used as intended, the x-direction will be approximately parallel to the longitudinal axis of the vehicle, while the y-direction will be approximately parallel to the transverse vehicle axis and the z-direction will be approximately parallel to the vertical axis of the vehicle.

Das Lichtmodul 10 weist eine Stützschale 12, eine Reflexionsschale 14 und eine Platine 16 auf und ist in der dargestellten Ausgestaltung durch eine geeignete Verbindung starr mit dem Schwenkrahmen 1 verbunden. Die geeignete Verbindung ist bevorzugt eine Schraubverbindung oder eine Nietverbindung.The light module 10 has a support shell 12, a reflection shell 14 and a circuit board 16 and, in the embodiment shown, is rigidly connected to the swivel frame 1 by a suitable connection. The suitable connection is preferably a screw connection or a rivet connection.

Figur 2 zeigt den Gegenstand der Figur 1 schräg von vorne, so dass eine Reflexionsfläche 18 der Reflexionsschale 14 erkennbar ist. Die Reflexionsschale 14 weist in der dargestellten Ausgestaltung zwei Reflektorkammern auf, was aber für die Erfindung nicht wesentlich ist. Ein Reflektor eines erfindungsgemäßen Lichtmoduls 10 kann auch nur eine oder auch mehr als zwei Reflektorkammern aufweisen. Figure 2 shows the subject of Figure 1 obliquely from the front, so that a reflective surface 18 of the reflective shell 14 can be seen. In the embodiment shown, the reflection shell 14 has two reflector chambers, but this is not essential for the invention. A reflector of a light module 10 according to the invention can also have only one or more than two reflector chambers.

In den Figuren 1 und 2 ist auch die Platine 16 zu sehen. Auf der in der Figur 2 sichtbaren Seite der Platine 16, die der Reflexionsfläche 18 zugewandt ist, ist jeweils eine Halbleiterlichtquelle 20 für jede Reflektorkammer sichtbar. Jede Halbleiterlichtquelle 20 weist wenigstens eine Leuchtdiode oder Laserdiode oder ein Feld von Leuchtdioden oder Laserdioden auf.In the Figures 1 and 2 the circuit board 16 can also be seen. On the in the Figure 2 On the visible side of the circuit board 16 facing the reflective surface 18, a semiconductor light source 20 is visible for each reflector chamber. Each semiconductor light source 20 has at least one light-emitting diode or laser diode or an array of light-emitting diodes or laser diodes.

Die der Figur 2 nach vorne offenen Schraubendohme 22 dienen zum Beispiel zum Anschrauben einer Blendeneinheit und/oder einer Linsenhaltereinheit an den Schwenkrahmen 1 des Lichtmoduls 10. Eine Blendeneinheit dient insbesondere zur Erzeugung einer Hell-Dunkel-Grenze einer Abblendlichtverteilung. Bei einer solchen Ausgestaltung wäre das erfindungsgemäße Lichtmodul ein Bestandteil eines sogenannten Projektionslichtmoduls, das eine Blendenkante der genannten Blende als scharfe Hell-Dunkel-Grenze abbildet. Das Lichtmodul kann aber auch ein direkt abbildendes Lichtmodul sein, bei dem der Reflektor die Lichtverteilung direkt aus dem Licht der Lichtquellen erzeugt, ohne dass dazu ein weiteres optisches Element in Form einer Linse oder eines weiteren Reflektors im Bündel des von der Reflexionsfläche ausgehenden Lichtes erforderlich ist.The the Figure 2 Screws 22 open to the front are used, for example, to screw a screen unit and / or a lens holder unit onto the swivel frame 1 of the light module 10. A screen unit is used in particular to generate a cut-off line for a low-beam light distribution. In such a configuration, the light module according to the invention would be a component of a so-called projection light module, which images a diaphragm edge of the said diaphragm as a sharp cut-off line. The light module can also be a direct be an imaging light module in which the reflector generates the light distribution directly from the light from the light sources, without the need for a further optical element in the form of a lens or a further reflector in the bundle of the light emanating from the reflective surface.

Die in der oberen Hälfte des Schwenkrahmens 1 sichtbaren geschlossenen Schraubendohme 24 dienen zur Aufnahme von Schrauben, mit denen die Stützschale 12 an den Schwenkrahmen 1 angeschraubt ist.The closed screw ends 24 visible in the upper half of the swivel frame 1 serve to hold screws with which the support shell 12 is screwed to the swivel frame 1.

Die in der unteren Hälfte des Schwenkrahmens 1 sichtbaren geschlossenen Schraubendohme 25 dienen zur Aufnahme von Schrauben, mit denen ein weiteres Lichtmodul, zum Beispiel ein Fernlichtmodul, mit einem zweiten Reflektor an dem Schwenkrahmen 1 befestigt wird.The closed screw ends 25 visible in the lower half of the swivel frame 1 serve to hold screws with which a further light module, for example a high beam module, is fastened to the swivel frame 1 with a second reflector.

Die Figuren 3 bis 5 zeigen vertikale Schnitte oder, im Fall der Figur 5 einen Teil eines vertikalen Schnitts durch den Gegenstand der Figuren 1 und 2.The Figures 3 to 5 show vertical cuts or, in the case of the Figure 5 part of a vertical section through the subject matter of Figures 1 and 2 .

Dabei zeigt die Figur 3 einen Schnitt, der in der Figur 1 in der y-Richtung etwa in der Mitte des Lichtmoduls 10 und parallel zur x-z-Ebene liegt und insbesondere eine Befestigung der Stützschale 12 am Schwenkrahmen 1 zeigt.The Figure 3 a cut that is in the Figure 1 lies in the y-direction approximately in the middle of the light module 10 and parallel to the xz-plane and in particular shows an attachment of the support shell 12 to the swivel frame 1.

Figur 3 zeigt insbesondere eine Stützschale 12 mit Reflexionsschale 14 und die Platine 16 mit einer Halbleiterlichtquelle 20. Bei der Halbleiterlichtquelle 20 handelt es sich um eine Leuchtdiode, ein Feld aus mehreren Leuchtdioden, eine Laserdiode, oder ein Feld aus mehreren Laserdioden. Figure 3 shows in particular a support shell 12 with reflection shell 14 and the circuit board 16 with a semiconductor light source 20. The semiconductor light source 20 is a light-emitting diode, an array of several light-emitting diodes, a laser diode, or an array of several laser diodes.

Die Stützschale 12 besteht aus einem ersten Material, und eine an der Stützschale 12 anliegende Reflexionsschale 14 besteht aus einem zweiten Material. Stützschale 12 und Reflexionsschale 14 bilden zusammen einen Reflektor mit Reflexionsfläche 18.The support shell 12 consists of a first material, and a reflection shell 14 resting against the support shell 12 consists of a second material. The support shell 12 and the reflection shell 14 together form a reflector with a reflection surface 18.

Der Grundwerkstoff des ersten Materials ist bevorzugt ein Leichtmetall wie Aluminium oder Magnesium oder eine wenigstens eines dieser Leichtmetalle enthaltende Legierung. Ein solcher Grundwerkstoff zeichnet sich durch eine gute mechanische Festigkeit und eine gute Wärmeleitfähigkeit aus. Seine Oberfläche bildet eine thermisch wirksame, das heißt Wärme aufnehmende und an die Umgebung abgebende Oberfläche des Reflektors, bzw. des Lichtmoduls 10. Durch die Auswahl dieses Grundwerkstoffes der thermisch wirksamen Oberfläche wird die Effektivität des Gesamtsystems erhöht, unter der hier die Effektivität einer Wärmeabfuhr aus den Lichtquellen und der Platine gemeint ist.The base material of the first material is preferably a light metal such as aluminum or magnesium or an alloy containing at least one of these light metals. Such a base material is characterized by good mechanical strength and good thermal conductivity. Its surface forms a thermally effective, i.e. heat-absorbing surface of the reflector or light module 10 that emits heat to the environment. The selection of this base material of the thermally effective surface increases the effectiveness of the overall system, under which the effectiveness of heat dissipation is increased the light sources and the circuit board is meant.

Das zweite Material ist zum Beispiel ein Kunststoff. Dieser Kunststoff bildet dann den Grundwerkstoff der optisch wirksamen Reflexionsfläche 18. Durch die Auswahl dieses Grundwerkstoffes werden Folgeprozesse, wie zum Beispiel ein Lackieren, unnötig. Alles in allem erlaubt die Aufteilung der Bauteilfunktionen auf unterschiedliche Werkstoffe die Vermeidung systembedingter Nachteile eines nur aus einem Material bestehenden Reflektors, der beim Stand der Technik sowohl die mechanischen, thermischen und optischen Funktionen erfüllen muss.The second material is, for example, a plastic. This plastic then forms the base material of the optically effective reflection surface 18. The selection of this base material makes subsequent processes, such as painting, unnecessary. All in all, the division of the component functions into different materials allows the avoidance of system-related disadvantages of a reflector consisting of only one material, which in the prior art must fulfill both the mechanical, thermal and optical functions.

Ein auf der Platine 16 angeordnetes Steckerelement 26 dient zur elektrischen Kontaktierung und Energieversorgung der Halbleiterlichtquelle 20. Mit einer Schraube 28 ist die Stützschale 12 des Reflektors im Lichtmodul 10 befestigt, zum Beispiel an einem Schwenkrahmen 1 des Lichtmoduls 10.A plug element 26 arranged on the circuit board 16 is used for making electrical contact and for supplying energy to the semiconductor light source 20. A screw 28 is the The support shell 12 of the reflector is fastened in the light module 10, for example on a swivel frame 1 of the light module 10.

Figur 4 zeigt einen Querschnitt durch das erfindungsgemäße Lichtmodul 10, der parallel zur x-z-Ebene verläuft und der etwa in der Höhe einer Befestigungsschraube, bzw. eines diese Schraube aufnehmenden Schraubendoms 32 liegt, mit denen die Platine 16 mit der Reflexionsschale 14 und der Stützschale 12 verbunden ist. Dabei zeigt Figur 2 insbesondere einen Schraubendohm 32 als Bestandteil der Stützschale 12 und eine Ausnehmung 34 in der Platine 16. Durch Eindrehen einer durch die Ausnehmung hindurch in den Schraubendohm 32 eingesetzten Schraube und Festziehen der Schraube wird die Platine 16 mit der Stützschale 12 mechanisch fest verbunden. Dabei wird die Reflexionsschale 14 zwischen der Platine 16 und der Stützschale 12 eingeklemmt und damit befestigt. Figure 4 shows a cross-section through the light module 10 according to the invention, which runs parallel to the xz plane and which is approximately at the level of a fastening screw or a screw dome 32 that receives this screw, with which the board 16 is connected to the reflection shell 14 and the support shell 12 . It shows Figure 2 In particular, a screw resistor 32 as part of the support shell 12 and a recess 34 in the board 16. By screwing in a screw inserted through the recess into the screw resistor 32 and tightening the screw, the board 16 is mechanically firmly connected to the support shell 12. In this case, the reflection shell 14 is clamped between the board 16 and the support shell 12 and thus fastened.

Über den Befestigungseffekt hinaus ergibt sich auch eine thermische Kopplung zwischen Halbleiterlichtquelle 20, Platine 16 und Stützschale 12, über die in der Halbleiterlichtquelle 20 erzeugte Wärme aus der Platine 16 heraus in die bevorzugt auch als Kühlkörper dienende Stützschale 12 abgeleitet wird.In addition to the fastening effect, there is also a thermal coupling between semiconductor light source 20, circuit board 16 and support shell 12, via which heat generated in semiconductor light source 20 is dissipated from circuit board 16 into support shell 12, which is preferably also used as a heat sink.

Zur Abgabe der Wärme an die Umgebung weist die Stützschale 12 auf ihrer der Reflexionsschale 14 abgewandten Rückseite bevorzugt oberflächenvergrößernde Strukturen 36 auf. Diese oberflächenvergrößernden Strukturen 36 besitzen bevorzugt eine Form von Rippen, um Wärme an die Umgebung abgeben zu können. Die Rippen verlaufen bevorzugt parallel zu der x-z-Ebene. Mit dieser Anordnung wird eine bessere Wärmeabfuhr von der Leuchtdiode erreicht. Diese Form bietet gegenüber der Alternative von stiftförmigen Kühlstrukturen den Vorteil, auch eine zusätzliche versteifende Wirkung zu besitzen, was es erlaubt, leichte Stützschalen 12 mit vergleichsweise wenig Materialeinsatz zu verwenden.In order to dissipate the heat to the environment, the support shell 12 preferably has surface-enlarging structures 36 on its rear side facing away from the reflection shell 14. These surface-enlarging structures 36 preferably have the shape of ribs in order to be able to give off heat to the surroundings. The ribs preferably run parallel to the xz plane. With this arrangement, better heat dissipation from the light-emitting diode is achieved. Compared to the alternative of pin-shaped cooling structures, this form offers the The advantage of also having an additional stiffening effect, which makes it possible to use lightweight support shells 12 with comparatively little use of material.

Neben diesen angeformten Versteifungsstrukturen 36 weist die Stützschale 12 Befestigungselemente 38 zur Befestigung der Platine 16 auf. In der dargestellten Ausgestaltung sind die Befestigungselemente 38 Schraubendohme 32.In addition to these molded-on stiffening structures 36, the support shell 12 has fastening elements 38 for fastening the circuit board 16. In the embodiment shown, the fastening elements 38 are screw ends 32.

Figur 5 zeigt einen parallel zur x-z-Ebene und in der Nähe eines in y-Richtung seitlichen Randes des Lichtmoduls 10 liegenden Querschnitt durch ein erfindungsgemäßes Lichtmodul 10. Im Fall der Figur 5 ist der seitliche Rand der in Figur 1 linke Rand des Lichtmoduls 10. Die Reflexionsschale 14 und die Platine 16 weisen zueinander komplementäre und ineinandergreifende Positionierungsstrukturen 38, 40 auf, die von der Schnittebene der Figur 5 geschnitten werden. Figure 5 shows a cross section through a light module 10 according to the invention, parallel to the xz plane and in the vicinity of a lateral edge of the light module 10 in the y direction Figure 5 is the side edge of the in Figure 1 left edge of the light module 10. The reflection shell 14 and the board 16 have mutually complementary and interlocking positioning structures 38, 40, which are from the plane of the section Figure 5 get cut.

Es ist bevorzugt, dass weitere Positionierungsgeometrien vorhanden sind. Es ist insbesondere bevorzugt, dass auch in der Nähe des rechten Randes des Lichtmoduls 10 solche oder ähnliche Positionierungsgeometrien angeordnet sind.It is preferred that further positioning geometries are present. It is particularly preferred that such or similar positioning geometries are also arranged in the vicinity of the right edge of the light module 10.

Durch die Positionierungsstrukturen 38, 40 wird die Platine 16 und insbesondere eine auf der Platine 16 angeordnete Halbleiterlichtquelle 20 in einer durch die Fertigungsgenauigkeit der Positionierungsstrukturen 38, 40 definierten Genauigkeit relativ zum aus Stützschale 12 und Reflexionsschale 14 bestehenden Reflektor 12 fixiert. Die Positionierungsstrukturen sind bevorzugt Vorsprünge 38 in der Reflexionsschale 14, die spielfrei in dazu korrespondierende, d.h. passend dimensionierte Ausnehmungen 40 der Platine 16 greifen. Umgekehrt können die Positionierungsstrukturen auch Vorsprünge auf der Platine 16 sein, die spielfrei in dazu passend dimensionierte Ausnehmungen der Reflexionsschale 14 greifen.The positioning structures 38, 40 fix the circuit board 16 and in particular a semiconductor light source 20 arranged on the circuit board 16 with an accuracy defined by the manufacturing accuracy of the positioning structures 38, 40 relative to the reflector 12 consisting of the support shell 12 and reflection shell 14. The positioning structures are preferably projections 38 in the reflection shell 14, which engage in corresponding, ie suitably dimensioned, recesses 40 of the circuit board 16 without play. Conversely, the Positioning structures can also be projections on the circuit board 16, which engage in recesses of the reflective shell 14 that are dimensioned to match, without play.

Ähnliche oder gleiche Positionierungsstrukturen sind bevorzugt auch, beziehungsweise in der Platine 20 auf deren der Stützschale 12 zugewandten Seite und in, beziehungsweise an der Stützschale 12 angeordnet. Auch diese greifen spielfrei so ineinander, dass die Position der Stützschale 12 in Bezug auf die Leiterplatte 16 und damit in Bezug auf die Lichtquelle(n) 20 hochgenau festgelegt ist.Similar or identical positioning structures are preferably also or in the circuit board 20 on its side facing the support shell 12 and in or on the support shell 12. These also interlock without play in such a way that the position of the support shell 12 in relation to the printed circuit board 16 and thus in relation to the light source (s) 20 is determined with high precision.

Solche Positionierungsstrukturen sind bevorzugt auch in der Nähe des in der Figur 1 linken Randes des Lichtmoduls angeordnet.Such positioning structures are preferably also in the vicinity of the Figure 1 arranged on the left edge of the light module.

Figur 2 zeigt, dass die Stützschale 12 an ihrem lichtaustrittsseitigen Ende in die lichte Weite der Öffnung des lichtaustrittseitigen Endes hineinragende Vorsprünge 44 aufweist. Beim Einsetzen der Reflexionsschale 14 in die Stützschale 12 bilden jeder dieser Vorsprünge 44 jeweils einen Anschlag für einen lichtaustrittsseitigen Rand der Reflexionsschale 14. Bevorzugt weist die Stützschale wenigstens zwei solche Vorsprünge 44 auf, von denen jeweils einer von der rechten Seite und einer von der linken Seite in die genannte Öffnung hineinragt und einen Anschlag in der Seitwärtsrichtung (y-Richtung und Gegenrichtung) und einen Anschlag in der Lichtaustrittsrichtung (x-Richtung) bildet. Figure 2 shows that the support shell 12 has projections 44 protruding into the clear width of the opening of the end on the light exit side at its end on the light exit side. When the reflection shell 14 is inserted into the support shell 12, each of these projections 44 each form a stop for an edge of the reflection shell 14 on the light exit side. The support shell preferably has at least two such projections 44, one from the right side and one from the left side protrudes into said opening and forms a stop in the sideways direction (y-direction and opposite direction) and a stop in the light exit direction (x-direction).

Die Stützschale 12 und die Reflexionsschale 14 sind in dem Sinne zueinander passend geformt und dimensioniert, dass eine konvexe, ihrer Lichtaustrittsseite abgewandte Rückseite der Reflexionsschale 14 passgenau, spielfrei und unter leichter Vorspannung, durch eine konkave Fläche der Stützschale aufgenommen wird.The support shell 12 and the reflection shell 14 are shaped and dimensioned to match one another in the sense that a convex side facing away from their light exit side The back of the reflective shell 14 is a precise fit, free of play and with a slight bias, taken up by a concave surface of the support shell.

Durch diese Art der Verbindung von Reflexionsschale 14, Platine 16 mit Lichtquellen 20 und Stützschale 12 wird eine Reduzierung der Toleranzkette innerhalb eines lichttechnischen Systems möglich.This type of connection of the reflection shell 14, the circuit board 16 with the light sources 20 and the support shell 12 enables the tolerance chain to be reduced within a lighting system.

Claims (13)

  1. Light module (10) of a motor vehicle headlamp comprising a reflector, a heat sink and a circuit board (16) with a semiconductor light source (20), wherein the reflector comprises a support shell (12) of a first material and a reflection shell (14) of a second material abutting the support shell (12), wherein the reflection shell (14) and the circuit board (16) have complementary and positioning structures that engage in one another, and wherein the support shell (12) is thermally coupled to the circuit board (16) by a suitable connection, characterised in that the support shell (12) and the reflection shell (14) are shaped and dimensioned to fit one another in such a way that a convex rear side of the reflection shell (14) facing away from its light emission side is received by a concave surface of the support shell (12) in a precisely fitting manner, without play and under slight pretension.
  2. Light module (10) according to claim 1, characterized in that the semiconductor light source 20 has at least one light-emitting diode or laser diode or an array of light-emitting diodes or laser diodes.
  3. Light module (10) according to any one of the preceding claims, characterised in that the base material of the first material is a light metal such as aluminium or magnesium or an alloy containing at least one of these light metals.
  4. Light module (10) according to one of the preceding claims, characterized in that the second material is a plastic.
  5. Light module (10) according to one of the preceding claims, characterized in that the supporting shell (12) of the reflector in the light module (10) is fastened to a pivot frame (1) of the light module (10) by a suitable fastening means.
  6. Light module (10) according to one of the preceding claims, characterised in that the reflector shell (14) is clamped between the circuit board (16) and the support shell (12) and fastened thereto or is also fastened in the reflector shell (14).
  7. Light module (10) according to one of the preceding claims, characterized in that the supporting shell (12) has surface-enlarging structures (36) on its rear side facing away from the reflecting shell (14).
  8. Light module (10) according to claim 7, characterized in that the surface-enlarging structures (36) have a cooling fin shape or a pin shape.
  9. Light module (10) according to one of the preceding claims, characterised in that the positioning structures are projections (38) in the reflection shell (14) which engage without play in corresponding, i.e. suitably dimensioned, recesses (40) of the printed circuit board (16), or in that the positioning structures are projections on the printed circuit board (16) which engage without play in suitably dimensioned recesses of the reflection shell (14).
  10. Light module (10) according to claim 9, characterized in that similar or identical positioning structures are also arranged on, or in, the printed circuit board (20) on its side facing the supporting shell (12) and in, or on, the supporting shell (12) and are dimensioned in such a way that they engage in one another without play.
  11. Light module (10) according to one of the preceding claims, characterised in that the supporting shell (12) has projections 44 at its light-emitting end projecting into the clear width of the opening of the light-emitting end.
  12. Light module (10) according to claim 11, characterized in that the supporting shell has at least two such projections (44), one of which projects into said opening from the right side and one of which projects into said opening from the left side and forms a stop in the sideways direction and a stop in the light exit direction perpendicular to the sideways direction.
  13. Light module according to any one of the preceding claims, characterised in that the appropriate connection is a screw connection or a riveted connection.
EP17175679.4A 2016-07-08 2017-06-13 Multi-component reflector for light module of a motor vehicle headlight Active EP3270043B9 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE202016103680.1U DE202016103680U1 (en) 2016-07-08 2016-07-08 Multi-component reflector for light module of a motor vehicle headlight

Publications (3)

Publication Number Publication Date
EP3270043A1 EP3270043A1 (en) 2018-01-17
EP3270043B1 true EP3270043B1 (en) 2021-03-03
EP3270043B9 EP3270043B9 (en) 2021-07-14

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Application Number Title Priority Date Filing Date
EP17175679.4A Active EP3270043B9 (en) 2016-07-08 2017-06-13 Multi-component reflector for light module of a motor vehicle headlight

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EP (1) EP3270043B9 (en)
CN (1) CN107588395B (en)
DE (1) DE202016103680U1 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE202016103680U1 (en) * 2016-07-08 2017-10-12 Automotive Lighting Reutlingen Gmbh Multi-component reflector for light module of a motor vehicle headlight
DE102019108233A1 (en) * 2019-03-29 2020-10-01 Automotive Lighting Reutlingen Gmbh Light module for a motor vehicle headlight with n partial light modules arranged in a row next to one another

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
TWM326615U (en) * 2007-06-01 2008-02-01 Liang-Yung Huang Installment to gain more brightness for tube lamp
EP2163814B1 (en) * 2008-09-16 2020-03-11 HELLA GmbH & Co. KGaA Reflector for a lighting device for a motor vehicle
JP5471596B2 (en) * 2010-03-01 2014-04-16 市光工業株式会社 Vehicle lighting
US8408764B2 (en) * 2011-01-14 2013-04-02 Min Hsiang Corporation Vehicular lamp
AT512083B1 (en) * 2011-11-02 2013-07-15 Zizala Lichtsysteme Gmbh PROCESS FOR PRODUCING REFLECTORS AND LIGHT UNIT WITH REFLECTOR
AT513444B1 (en) * 2012-10-09 2014-07-15 Zizala Lichtsysteme Gmbh Light module with two or more reflectors for a motor vehicle and motor vehicle headlights
DE202016103680U1 (en) * 2016-07-08 2017-10-12 Automotive Lighting Reutlingen Gmbh Multi-component reflector for light module of a motor vehicle headlight

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
None *

Also Published As

Publication number Publication date
DE202016103680U1 (en) 2017-10-12
EP3270043A1 (en) 2018-01-17
EP3270043B9 (en) 2021-07-14
CN107588395A (en) 2018-01-16
CN107588395B (en) 2022-02-11

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