EP3343091B1 - Light module for motor vehicle headlamps - Google Patents

Description

The present application relates to a light module for a motor vehicle headlight according to the preamble of claim 1. Such a light module is in each case from EP 3 163 155 A1 , of the EP 1 936 260 A1 and the EP 3 299 703 A1 known.

A light module known per se has at least two semiconductor light sources, one for each semiconductor light source individual ancillary optics, a light decoupling optics having at least one partial optics and a diaphragm arranged between the ancillary optics and the light decoupling optics, the light module being set up to produce at least two different rule-compliant light distributions individually or in any combination.

From the DE 10 2014 226 650 A1 is a lamp known that has at least three light functions such as low beam, High beam, daytime running light and / or position light implemented. The low beam is analogous to the description in U.S. 6,948,836 and the high beam and daytime running lights in a similar manner as in the DE 10 2008 036 192 generated.

The U.S. 6,948,836 discloses a low beam module which creates a light-dark boundary by means of an approximately horizontally lying mirrored screen. The light used to generate a low beam distribution is generated by a semiconductor light source and bundled by a reflector. The bundled light is directed from above onto the front edge of the screen. An image of the diaphragm edge is projected onto the road as a light-dark boundary of a low beam distribution using a light decoupling lens implemented as a projection lens. In this application, location information such as above and below always relate to an alignment of the light module that corresponds to its alignment when used as intended in a motor vehicle.

From the DE 10 2008 036 192 A1 an LED bi-function module for generating a low beam and high beam distribution of a motor vehicle headlight is known. The horizontal cover is made thin here and is also illuminated from below to generate the high beam. Reflectors or catadioptric optics are used to collimate the LED light.

Based on the prior art described at the outset, the task is to construct a light module that is as compact as possible, with which at least two rule-compliant light distributions can be generated. The two light distributions are preferably a low beam distribution and a high beam distribution.

At the same time, the light module should be made as simple as possible. The different light distributions are, for example, a light distribution optimized for the motorway or for the city or for right-hand traffic or for left-hand traffic.

This object is achieved with the features of claim 1.

The features of claim 1 provide that a lens combination is arranged between the light extraction optics and the diaphragm, which is illuminated by at least one of the at least two semiconductor light sources and from which the light from this semiconductor light source emerges in a light cone, the lens combination in two with each other and in the main direction of propagation of the light emitted by the light module perpendicular spatial directions has a different refractive power and that the light decoupling optics, which are arranged in the light cone of the lens combination, have a different refractive power in two directions perpendicular to each other and to the main propagation direction of the light emitted by the light module, the refractive power of the light decoupling optics in the spatial direction in which the lens combination has the smaller of its two refractive powers and where the lens combination is closer to the diaphragm than to the light coupling optics ang is arranged, wherein the light module has at least one low beam channel and at least one high beam channel, each low beam channel having a light source, a light from this light source collecting and focusing lens, an elevation of the diaphragm, and a projection lens system, which consists of a lens-shaped section of the lens combination or a single lens the lens combination and the light decoupling optics, each part of the lens combination or each individual lens of the lens combination being arranged in the light cone of exactly one ancillary optics, and that an ancillary optics-side focal length of the projection lens system in each high beam channel is greater than in each low beam channel, and that at least two low beam channels have different diaphragm shapes.

The lens combination can also consist of a number of Individual lenses exist. The number of lenses preferably corresponds to the number of ancillary optics. Each lens, or each part of the lens combination, is preferably arranged in the light cone of precisely one lens attachment and is illuminated with light from a light source. The individual lenses are arranged in a row running transversely to the main direction of light propagation. The light decoupling optics consists of a single lens assigned to all individual lenses.
A pair of an ancillary optics and the lens lying in the light cone of this ancillary optics, or the part of the lens combination lying in the light cone of this ancillary optics and the light decoupling optics following in the light path, form a light channel. The various light channels run separately from one another between the auxiliary optics and the lens or part of the lens combination. The two light distributions can also be parts of a single rule-compliant light distribution, for example a low beam distribution or a high beam distribution, the individual channels only generating different partial light distributions. Then the cover has only a continuous shape or, in the case of a high beam distribution, can also be missing. The lens combination, together with the light extraction optics, forms a projection lens system, each lens-shaped section of the lens combination, together with the light extraction optics, fulfilling the function of a light channel-individual projection lens. The focal lengths of these light channel-individual projection lenses on the front optics side are greater for the high beam channels than for the low beam channels.

In particular for the generation of high beam and low beam, there are stipulations by law and by automobile manufacturers as to which angular areas should be illuminated. As a rule, the angular ranges are of different sizes in the horizontal and vertical directions. In the case of low beam, this can be a ratio of 5: 1 (approx. 100 ° horizontal width, approx. 20 ° vertical height). If such a ratio is to be generated in an intermediate image area at the diaphragm edge, the width of the diaphragm must also be correspondingly large. Accordingly, light modules must have a certain size in order to generate such a light distribution. If several light sources are generated to generate a rule-compliant light distribution or several different light functions are implemented in one module, this means that the overall system has to be larger, which is contrary to a compact solution.

Because the lens combination and the light decoupling optics each have a different refractive power in different spatial directions, a distorted image is generated which solves this problem. The lens combination (or the lenses), which is arranged after a diaphragm that may be present in the light path, ensures a more or less strong focus in one direction, while the light decoupling optics realize this for a second direction. The combination of lenses preferably ensures, above all, concentration in the spatial direction in which a larger angular range is to be illuminated. The bundling in the other spatial direction is mainly realized by the light decoupling optics. This second bundling essentially causes the light beams to be parallelized.

In the case of a headlight, the spatial directions are a vertical spatial direction and a horizontal spatial direction when the front light is used as intended. The lens combination preferably bundles in the horizontal, while the optical coupling-out optics preferably bundles in the vertical. For the compactness of the light module, it is also advantageous if the lens combination (or the lenses fulfilling their optical function) is located close to the intermediate image surface, that is, close to the side or edge of the diaphragm facing the light exit optics. The reason for this is that the ancillary optics are usually designed in such a way that the light bundles from the individual light sources are most closely bundled there. It is particularly preferred that the lens combination (or the lenses fulfilling its optical function) is located closer to the side or edge of the diaphragm facing the light exit optics than to the light exit optics. The lens combination (or the lenses fulfilling their optical function) is preferably located in the light path between the edge of the diaphragm and the light exit optics.

This optical concept ensures that the light module has a simple and at the same time compact structure.

In this context, simple means that the number of components is small (preferably, but not necessarily less than 12 components per module, light sources and fastenings such as screws not counted), that no mechanically movable parts are required to generate the different light distributions, and that all components can be manufactured inexpensively and in large numbers using conventional manufacturing processes.

In this context, compact means that the module preferably, but not necessarily, has a height of less than 75 mm, a depth of less than 130 mm and a width of less than 150 mm.

It is preferred that the light emitted by the light module is, in addition to the rule-compliant low beam and high beam, also a rule-compliant daytime running light and / or position light and / or flashing light and / or cornering light and / or motorway light and / or town light and / or partial high beam and / or marker light, The light module should be able to generate at least one of these additional light distributions, possibly also for different types of traffic (left-hand traffic, right-hand traffic) or regulation variants (ECE (Europe), SAE (USA), CCC (China)). Of course, this list is not limited to the light distributions mentioned, but can also contain other light distributions.

It is further preferred that the light exit optics have a further sub-optics and that the ancillary optics of at least one of the semiconductor light sources is set up and arranged to direct light from this semiconductor light source past the lens combination onto the further sub-optics and that the further sub-optics are set up to distribute light to generate, which is different from the light distributions of the light that propagates through the lens combination.

This refinement is particularly advantageous when realizing light distributions with a light module if the requirements for the light distribution differ significantly. This is the case, for example, with a flashing light distribution and a high beam distribution. Due to the different requirements, different optics are necessary in order to generate the desired light distribution, in particular different light decoupling optics. By arranging both optics in one light module, compared to solutions with separate Optics and / or light modules save space and components.

It is also preferred that all semiconductor light sources are arranged on a flat circuit board which is attached to a one-piece heat sink.

Advantageously, the costs for connectors, cable harness and circuit boards are significantly reduced, and all semiconductor light sources use a common heat sink. In this way, the total heat sink volume can be reduced, which reduces weight and costs.

It is also preferred that the ancillary optics is a catadioptric optic and / or a reflector and / or a lens and / or an imaging lens system and / or a light guide.

Depending on the existing installation space, the intended application of the light module or the design requirements, it is advantageous to use different front optics. Due to the fact that each light source has an individual ancillary optics, it can be advantageous to use different ancillary optics in one and the same light module due to the different requirements for the light distributions. In principle, it is provided that even when using the same type of ancillary optics for all light sources, this ancillary optics is designed individually for each light source, depending on the requirements.

It is preferred here that the optical attachment is a one-piece optical attachment combination which comprises the optical attachment of all semiconductor light sources. This advantageously further reduces the installation space required, the number of components and thus the weight and costs.

It is also preferred that the semiconductor light sources are arranged in a matrix-like manner in rows, with individual or multiple rows of semiconductor light sources being set up to jointly generate at least one rule-compliant light distribution. The lines can also be arranged offset to one another.

In this context, matrix-like is also to be understood as meaning that several semiconductor light sources are arranged at a distance from one another in a row and that a second row of semiconductor light sources, which are also arranged at a distance from one another, is positioned offset to the first row above or below it . This results in the advantage of a compact installation space. The additional optics require a significantly larger installation space than the light sources and are therefore largely responsible for the necessary installation space. The staggered arrangement makes better use of the available space, since the ancillary optics are also arranged correspondingly offset from one another. In this case, individual rows are provided for generating a single light distribution (or part of a light distribution), for example a row for a low beam and a row for a high beam, which simplifies the construction. In order to save even more space, it is possible to use several rows to generate the same light distribution, for example two rows to generate a low beam distribution.

It is preferred that the screen has a screen surface with a combination of at least one elevation and at least is a depression, the elevation being arranged in the light path of a low beam source and the depression in the light path of a high beam source. The profiles of the diaphragm in which the elevations and depressions are located are arranged transversely to the main direction of light propagation.

Advantageously, light channels that require a screen to generate a rule-compliant light distribution, such as a low beam, and light channels that do not require a shutter to generate a rule-compliant light distribution, such as a high beam, can be installed in close proximity to one another to save space. With several smaller elevations serving as screens, less space is required for the entire light module than with a single large screen, which has a single, continuous screen edge, and the use of a single component as a unit of several small screens reduces the number of components required .

It is further preferred that some of the elevations, for example all with the exception of a single elevation, each have a step for generating an image of the step in the form of a light-dark boundary in the low beam distribution. Each step has an edge running parallel to the main direction of propagation of the light.

A bright and glare-free light distribution is initially generated by the elevations having steps. The channel or channels that do not have steps are preferably designed in such a way that they scatter the light more broadly than the channels that have steps. In this way, for example, light can be scattered into areas that are shaded by the channels having steps. In this way, an even if low brightness can be generated there which, for example, allow traffic signs to be recognized without unduly dazzling other road users.

It is preferred that an edge of the diaphragm facing the light extraction optics is arranged in a focal area of the ancillary optics and in a focal area of the projection lens system consisting of the lens combination (or the functionally equivalent lenses) and the light extraction optics (the focal areas of the lens combination (or the functionally equivalent lenses) and of the light decoupling optics form common focal areas that overlap with the focal area of the ancillary optics).

In this way, the diaphragm edge is advantageously mapped sharply, which ensures a sharp light-dark boundary in a low beam distribution.

It is also preferred that at least one lens-shaped section of the lens combination (or a functionally equivalent single lens) is arranged in the light cone of precisely one lens attachment.

This configuration is particularly advantageous when using several light sources because the contribution of each light source to the overall light distribution can then be configured individually by the shape of the associated section. This also opens up the possibility of producing certain changes in the light distributions by changing the refractive surfaces of the lens combination (or the functionally equivalent individual lenses) with otherwise unchanged light modules.

In a preferred embodiment, the first partial optics the light decoupling optics a cylindrical lens.

The advantage of this configuration is the simple production and compact design, which at the same time offers a wide light exit surface.

It is preferred that the additional partial optics of the light decoupling optics is a structured disc and / or cushion optics and / or consists of a volume-scattering material, i.e. a material in which the scattering occurs at least not only on the surface but also on scattering centers in the volume .

The result is a widely spread light distribution, which is suitable, for example, for a rule-compliant flashing light distribution.

A part of the light module which is set up to generate a rule-compliant daytime running light distribution is preferably also set up to generate a rule-compliant turn signal distribution.

It is also preferred that light functions which have a similar light distribution use the same components of the light module, in particular the light decoupling optics should be mentioned here.

This results in a more compact design of the light module with simultaneously reduced costs. Standard-compliant daytime running light and indicator light distributions both illuminate a similar angular range. It is therefore expedient to use at least some of the same components within the light module for generating these two light distributions.

In a preferred embodiment, the optical coupling-out system is a one-piece component.

In addition to the reduced costs for the component, the installation space is also reduced and assembly is simplified.

It is further preferred that at least one vertical diaphragm is arranged in the light path of at least one high beam source and is set up to limit the illuminated angular range of the high beam source.

In this way, the implementation of a partial high beam is advantageously conceivable, in which individual light sources are switched off or dimmed to prevent dazzling road users.

According to the invention, the light module has at least one low beam channel and at least one high beam channel, each low beam channel consisting of a light source, an auxiliary lens that collects and focuses light from this light source, and a projection lens system that consists of a lenticular section of a lens combination or a single lens of the lens combination and a light extraction lens, wherein each part of the lens combination, or each individual lens of the lens combination is arranged in the light cone of exactly one ancillary optics and wherein an ancillary optics-side focal length of the projection lens system in each high beam channel is greater than in each low beam channel.

According to the invention, at least two low-beam light channels have a different aperture shape, so that different light distributions can be generated by switching between the channels or by suitable dimming of each channel, for example one for the motorway or light distribution optimized for the city or for right-hand traffic or for left-hand traffic. Switching or dimming is done by activating the light sources of the channels accordingly.

It is further preferred that the optical coupling-out system is arranged tilted about a vertical axis or is curved.

External conditions, such as the arrowheading of the cover plate of the headlight, can thus advantageously be taken into account.

It is also preferred that a control device of the headlight which controls the semiconductor light sources is set up to dim semiconductor light sources which are used to generate a rule-compliant high beam distribution in order to generate and / or supplement a rule-compliant daytime running light distribution.

This advantageously increases the luminous area of the headlight in daytime running lights, which further improves the visibility of the motor vehicle. Another advantage is that an assembly serving only to generate daytime running lights can be omitted.

The light module, in particular the board on which the semiconductor light sources are arranged, and the control device controlling the semiconductor light sources are preferably set up to control the semiconductor light sources individually or in groups, for example to dim them.

Depending on the traffic situation, type of traffic or legal requirements, individual light sources can advantageously be switched on and off, whereby functions to increase safety, for example a static cornering light that works without moving parts or a partial high beam, can be implemented or country-specific requirements can be met .

Further advantages emerge from the following description, the drawings and the subclaims. 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 alone, without departing from the scope of the present invention. Exemplary embodiments of the invention are shown in the drawings and are explained in more detail in the following description.

Figur 1

ein Ausführungsbeispiel eines erfindungsgemäßen Lichtmoduls in einer dreidimensionalen Ansicht mit Gehäuse;

Figur 2

das Lichtmodul aus Figur 1 in einer dreidimensionalen Ansicht ohne Gehäuse;

Figur 3

das Lichtmodul aus Figur 1 in einer dreidimensionalen Ansicht von oben;

Figur 4

das aus Figur 1 Lichtmodul in einer Seitenansicht;

Figur 5

eine Draufsicht auf das Lichtmodul der Figur 1;

Figur 6

eine Komplexlichtquelle des erfindungsgemäßen Lichtmodul aus Figur 1;

Figur 7

eine dreidimensionale Vorderansicht der Lichtquellen auf einer Platine;

Figur 8

Strahlengänge der Abblendlichtkanäle in dem Lichtmodul aus Figur 1 in der Draufsicht;

Figur 9

einen Strahlengang eines Abblendlichtkanals entlang der keine Stufe aufweisenden Blende in dem Lichtmodul aus Figur 1;

Figur 10

Strahlengänge der Fernlichtkanäle in dem Lichtmodul aus Figur 1;

Figur 11

Vergleich der Strahlengänge von Abblendlicht und Fernlicht in dem Lichtmodul aus Figur 1;

Figur 12

Strahlengänge der Tagfahrlicht-/Positionslichtkanäle in dem Lichtmodul aus Figur 1;

Figur 13

Strahlengänge unterschiedlicher Lichtkanäle in dem Lichtmodul aus Figur 1 in einer Seitenansicht; und

Figur 14

Strahlengänge unterschiedlicher Lichtkanäle in dem Lichtmodul aus Figur 1 in einer dreidimensionalen Ansicht

Show, each in schematic form:

Figure 1

an embodiment of a light module according to the invention in a three-dimensional view with housing;

Figure 2

the light module off Figure 1 in a three-dimensional view without the housing;

Figure 3

the light module off Figure 1 in a three-dimensional view from above;

Figure 4

the end Figure 1 Light module in a side view;

Figure 5

a top view of the light module of Figure 1 ;

Figure 6

a complex light source of the light module according to the invention Figure 1 ;

Figure 7

a three-dimensional front view of the light sources on a circuit board;

Figure 8

Beam paths of the low beam channels in the light module Figure 1 in plan view;

Figure 9

a beam path of a low beam channel along the diaphragm not having a step in the light module Figure 1 ;

Figure 10

Beam paths of the high beam channels in the light module Figure 1 ;

Figure 11

Comparison of the beam paths from low beam and high beam in the light module Figure 1 ;

Figure 12

Beam paths of the daytime running light / position light channels in the light module Figure 1 ;

Figure 13

Beam paths of different light channels in the light module Figure 1 in a side view; and

Figure 14

Beam paths of different light channels in the light module Figure 1 in a three-dimensional view

The same reference symbols denote different ones Figures are identical or at least functionally comparable elements.

In detail, the Figure 1 a light module 8 according to the invention of a motor vehicle headlight, which is shown in this exemplary embodiment with its housing 10. On the front of the housing 10 of the light module, a light decoupling optics 9 is formed by a partial optic 9B and a further partial optic 9A. The further partial optics 9A is a structured disk in the exemplary embodiment shown, and the partial optics 9B is a cylindrical lens in the exemplary embodiment shown. The further partial optics 9A are arranged in a beam path of a daytime running light distribution and / or position light distribution, while the partial optics 9B is arranged in the beam path of a low beam distribution and / or high beam distribution. Cylindrical lens and structured disk are preferably each individually or as a whole a one-piece component, which lowers the number of individual parts and thus the costs for production. The light module described here and below is an advantageous development of the invention and is capable of generating at least two different rule-compliant light distributions.

On the rear of the housing 10 of the light module 8 there is a cooling body 16, which has a plurality of cooling fins 18 in the form of representation shown.

Furthermore, an arm for the mechanical headlight range control 20 is attached to the underside of the housing 10 on the latter. An axis of rotation 24 of the headlight range control is defined by a suspension 22 attached to the side of the housing 10. At the bottom of the boom, an actuator, not shown, engages the boom and thus the entire light module 8 is pivoted in the plane perpendicular to the axis of rotation 24.

In the Figure 2 is the light module 8 according to the invention from Figure 1 shown without housing. The heat sink 16 with its ribs 18 has bores 26 which are intended for fastening other components such as the housing 10, not shown, for example. Between the heat sink 16 and the light decoupling optics 9 formed by the structured disk and the cylinder lens, there are further components which are intended to generate a rule-compliant light distribution.

A circuit board 28, on which the semiconductor light sources 70, which are not visible in this illustration, are located, preferably LEDs, is fastened directly to the heat sink 16. In front of the board 28, an attachment optics combination 30 is fastened, which consists of several daytime running light attachment optics 32, low beam attachment optics 34 and high beam attachment optics 36. These individual parts of the optical attachment combination 30 are arranged in the optical attachment combination 30 such that each individual part forms an individual optical attachment for a single semiconductor light source 70 on the board 28 when the optical attachment combination 30 is used as intended. In this case, the low-beam headlights 34 and the high-beam headlights 36 are each arranged alternately next to one another in a row. The daytime running light attachment optics 32 are located in a further row above the low beam and high beam attachment optics 34 and 36.

In the light path after the front lens combination 30 is a diaphragm combination 38, which as a diaphragm for the Low beam distribution acts. The diaphragm combination 38 has a plurality of alternating depressions 40 and elevations 42 which are arranged transversely to the main direction of light propagation in such a way that in each case a depression and an elevation alternate. The elevations form the screens for the respective light channels. The elevations 42 are arranged in the beam paths of the low beam attachment optics 34, and the depressions 40 are arranged in the beam paths of the high beam attachment optics 36. A step 44 in the panel surface can be seen in three of the four elevations shown. These steps 44 are used to generate a step in the cut-off line of a rule-compliant low beam distribution. In the exemplary embodiment shown, one of the four elevations 42 has a surface 46 without a step, but this is not an essential feature of the invention.

In principle, it is also possible to use several individual diaphragms instead of a diaphragm combination 38. In order to reduce the number of components of the light module 8, a configuration in the form of the one-piece panel combination is preferred. Furthermore, it is in principle also possible that the diaphragm combination is only narrow along the main direction of light propagation (e.g. like the narrow side of a metal sheet that is less than 1 mm thick, for example) so that the elevations and depressions only represent parts of a contoured edge of a thin sheet metal . In this case, the screen can also extend in the vertical direction starting from the optically effective screen edge. The optically effective screen edge is then an upper edge of the screen.

A lens combination 48 is located in the light path behind the diaphragm combination 38. In the embodiment shown, the lens combination 48 has, with the exception of one The convex protrusion 56 on the light entry side has a flat light entry surface 50. The convex protrusion 56 is set up to receive light that propagates in the low-beam light channel in which the associated diaphragm elevation 42 does not have a step 46.

The light exit surface 52 of the lens combination consists of high beam exit areas 58 and low beam exit areas 60 arranged next to one another, which are arranged so that each of the light exit areas is illuminated by only one combination of semiconductor light source 70 and its ancillary optics. The lens combination (or individual lenses fulfilling their optical function) is preferably located in the light path between the edge of the diaphragm and the light exit optics and is arranged in such a way that each section or each functionally equivalent individual lens captures as much as possible all of the light rays of the light source emanating from the associated ancillary optics. A low beam exit surface 60 is arranged next to a high beam exit surface 58, so that two low beam channels are separated by a high beam channel located between them and two high beam channels are separated by a low beam channel located between them. The light module is completed by the already described light decoupling optics 9, which consist of a structured disk and cylinder lens. A different arrangement of the high beam channels and the low beam channels is also possible, in which the low beam channels lie next to one another without a high beam channel lying between them and / or in which the high beam channels lie next to one another without a low beam channel lying between them.

In the Figure 3 is that in the Figure 2 The light module 8 shown is shown in a further three-dimensional view obliquely from above. From this perspective it can be seen that the circuit board 28 rests directly (in thermal contact) on the heat sink 16 having cooling fins 18, while the front lens combination 30, the diaphragm combination 38, the lens combination 48 and the light extraction lens 9 do not have to adjoin one another directly, but rather through between them lying gaps are arranged separately from each other.

The flat light entry surface 50 of the lens combination 48 with the convex protrusion 56 can also be seen particularly clearly, as well as the different designs of the alternating high beam exit surfaces 58 and low beam exit surfaces 60 of the light exit surface 52 of the lens combination 48. Furthermore, a holder 62 is attached to the light decoupling optics 9 for attachment the light decoupling optics 9 attached to the housing 10 of the light module 8, not shown in this figure.

In the Figure 4 the light module 8 consisting of heat sink 16, circuit board 28, front lens combination 30, diaphragm combination 38, lens combination 48 and light decoupling optics 9 consisting of structured disk (further partial optics 9A), cylinder lens (partial optics 9B) and holder 62 is shown in a side view.

A plug 64 is attached to the circuit board 28 below the optical attachment combination 30, which serves as an interface for supplying energy to the semiconductor light sources 70 attached to the circuit board and for controlling the semiconductor light sources 70 by a light control device 68 serves.

The different design of the individual components of the front lens combination 30 can be clearly seen. The daytime running light front lens 32, the low beam front lens 34 and the high beam front lens 36 have different designs. They differ depending on the type of light distribution to be generated, especially in their size. It can also be seen that the center points of the low-beam headlights 34 and the high-beam headlights 36 are not at the same height, but rather are arranged vertically offset from one another due to the different sizes of the headlights, so that a checkerboard-like offset arrangement results in which the low-beam headlights in one in the first row and the high-beam headlights are in a further row that is vertically offset. The smaller high beam attachment optics 36 are lower than the low beam attachment optics 34.

In Figure 5 the same light module 8 can be seen in a plan view. In detail, the Figure 5 the heat sink 16 with cooling fins 18, circuit board 28, front optics combination 30, diaphragm combination 38, lens combination 48 and light decoupling optics 9 consisting of a structured disk (further partial optics 9A), cylinder lens (partial optics 9B) and holder 62.

It can be seen that a light exit surface 60C of the lens combination 48, which belongs to the light channel, in whose associated part of the diaphragm combination 38 the elevation 42 of the diaphragm combination 38 does not have a step, has a different shape than the other light exit surfaces 60A, 60B, 60D of the lens combination 38 for the low beam sources 74.

Since each semiconductor light source 70, with the exception of the light decoupling optics 9, always has its own optics (associated part of the front lens combination 30, associated part of the diaphragm combination 38 and associated part of the lens combination 48), individual light channels are formed within the light module. According to the light sources shown here, there are daytime running light channels 82, low beam light channels 84 and high beam light channels 86.

Figure 6 shows a unit of heat sink 16 with cooling fins 18, plate 28 and front optics combination 30 consisting of daytime running light front optics 32, low beam front optics 34 and high beam front optics 36 in a three-dimensional front view. This unit forms a so-called complex light source 66. In the Figure 7 was opposite the Figure 6 the optical attachment combination 30 removed so that the underlying structure of the circuit board 28, which is attached to the heat sink 16, can be seen. The circuit board 28 carries several, in the present example ten, semiconductor light sources 70. The lower row of four semiconductor light sources are high beam sources 72, the middle row has four low beam sources 74, and the upper row has daytime running light sources 76.

To save space, the low beam sources 74 and the high beam sources 72 are offset and arranged in rows one above the other. The use of further semiconductor light sources is conceivable, in which case further rows of alternating low beam sources 74 and high beam sources 72 are preferably arranged further offset one above the other.

The daytime running light sources 76 are also preferred as Flashing light sources and / or designed as position light sources. A light source can consist of several chips, for example, which may also emit light of different colors (for example red, green and blue to generate white or yellow light).

The high beam sources 72 can optionally also be used as additional daytime running light sources. To do this, they are dimmed and not operated at full power in order to prevent oncoming traffic from being dazzled.

Of course, the number of in the Figure 8 The light sources shown are not limited to the number shown there and can be adapted to the respective needs and accompanying circumstances.
The semiconductor light sources 70 are not necessarily light-emitting diodes. For example, individual or all semiconductor light sources can also be implemented using laser light sources.

In the Figure 8 the beam paths of the four low beam channels 84 are shown. In detail, each of the four channels has the following elements: A low beam source 74 consisting of a semiconductor light source, a low beam lens system 34, elevations 42 of the horizontally extending diaphragm combination 38 functioning as a diaphragm, a lens combination 48 with low beam exit surfaces 60 in the form of a projection lens and a cylinder lens as Light decoupling optics 9B.

Light which is generated by the low-beam light sources 74 is deflected by the low-beam attachment optics 34 which are individually associated with a low-beam light source 74 and which in the present case are catadioptric optics and bundled. Low beam source 74 and front lens 34 are arranged higher in the vertical direction than the diaphragm combination 38 and are designed to direct the light obliquely from above onto the diaphragm combination 38, which preferably, but not necessarily, has a mirrored surface. The focal area of the low beam attachment optics 34 lies on the diaphragm edge 80 of the diaphragm combination 38, which diaphragm edge 80 faces the lens combination 48. This creates an intermediate image of a light distribution with a light-dark boundary in the plane of the diaphragm edge 80, the shape of which is determined by the shape of the diaphragm edge 80.

In three of the four light channels 84A, 84B, 84D shown in this light module, the elevations 42 are provided with a step 44 which creates a step in the course of the light-dark boundary of the low beam distribution. A light channel 84C is focused on a piece of the diaphragm edge 80 which does not have a step 44 and accordingly the light-dark boundary of the part of the low-beam light distribution generated by this light channel does not have a corresponding step.

The diaphragm edge 80 is at the same time also in the focal area of the light entry surface 50 of the lens combination 48. While the light entry surface 50 is a straight and flat surface with the exception of a convex protrusion 56 in the low beam channel 84C, the light exit surface 52 has one for each low beam channel 84A, 84B, 84C, 84D individual low beam exit surface 60A, 60B, 60C, 60D in the form of a projection lens. Each low beam channel 84A, 84B, 84C, 84D has exactly one single low beam exit surface 60A, 60B, 60C, 60D available exclusively.

In the light module 8 shown, the lens combination 48 also has high beam exit surfaces 58, which are described in more detail in a description of the high beam channels 86. The high beam and low beam exit surfaces 58 and 60 are arranged alternately next to one another.

The low-beam light channels 84A, 84B, 84C, 84D pass through their respective associated part of the lens combination 48. The low-beam light exit surfaces 60 of the lens combination 48 are shaped so that they are more focused horizontally than vertically. Therefore, the part of the intermediate image generated by one of the low beam light sources 74 is enlarged primarily in the vertical direction. This contributes to the desired compactness of the light module 8. Due to the small horizontal installation space requirement, the semiconductor light sources 70 can be arranged compactly next to one another and / or in two rows one above the other and, if necessary, offset from one another in the longitudinal direction of the rows. The lens combination (or the functionally equivalent individual lenses) preferably has no curvature in the vertical direction and is therefore cylindrical in the vertical direction. An enlargement of the intermediate image, of the light distribution in the focal area of the light decoupling optics on the visor side, results from the interaction of the lens combination and the light decoupling optics. In this case, the magnification in the horizontal direction is preferably greater than in the vertical direction, these directional information always relating to an alignment as it results when the light module is used as intended in a motor vehicle.

The light emanating from the low beam light sources 74 then hits the partial optics 9B of FIG Light decoupling optics 9. The partial optics 9B here has the shape of a (horizontal) cylinder lens, the cylinder axis of which in the example shown is a horizontal perpendicular to the main emission direction of the light module. The light emerging from the cylinder lens generates the rule-compliant low beam distribution.

Since the lens combination 38 bundles more horizontally than vertically and the cylindrical lens bundles more vertically than horizontally, a distorted image is produced, that is, the vertical and horizontal image scale are not the same. In this example the horizontal bundling is weaker than the vertical bundling. This is advantageous because a low beam distribution typically has a width of up to 100 ° and a height of up to 20 °. This corresponds to a width to height ratio of around 5: 1. If such a ratio is to be generated already in the intermediate image area at the diaphragm edge 80 in a conventional system, the width of the diaphragm combination 38 must also be made correspondingly larger. However, this means that the light module 8 has to be wider, which is contrary to a compact solution. The distorted imaging projection lens system thus also has the effect of reducing the installation space required for the low beam channels 84A, 84B, 84C, 84D.

Each channel preferably has differences with regard to the design of the auxiliary optics, the elevation 42 in the diaphragm combination 38 and the low beam exit surface 60 of the lens combination 52. The entire low-beam light distribution is only created by the overlapping superposition of the individual light distributions of the low-beam light channels 84A, 84B, 84C, 84D. Three low beam channels 84A, 84B, 84D have an elevation 42 with level 44. A channel 84C has an elevation 42 without a step.

In Figure 9 the beam path of the low beam channel 84C within the light module 8 according to the invention is shown.

The light generated in the low-beam light source 74C, which is designed as a semiconductor light source, also passes through the low-beam attachment optics 34 of the attachment optics combination 30, hits an elevation 42 of the approximately horizontal diaphragm combination 38, passes through the lens combination 48 with low-beam exit surfaces 60 in the form of a projection lens, and leaves the light module through the cylinder lens.

The light entry surface 50 of the lens combination 48 for this low beam channel 84C has the convex protrusion 56 in the form of a further projection lens, which is horizontally more curved than the light exit surface 60C of the channel. The effect is that the rays are focused in a plane between the light entry surface 50 and the light exit surface 60C in order to then diverge again. Overall, this achieves a fanning out of the beams in the horizontal plane and the width of the light distribution is increased. This effect can also be achieved in that the lens is concave and thus acts horizontally as a diverging lens.

In the Figure 10 the beam paths of the four high beam channels 86 are shown. In detail, each of the four channels has the following elements: A high beam source 72 consisting of a semiconductor light source, high beam attachment optics 36 as part of the attachment optics combination 30, a depression 40 in the approximately horizontal diaphragm combination 38, the lens combination 48 with high beam exit surfaces 58 in the form of a projection lens and the cylinder lens as part of the light decoupling optics 9.

Light which is generated by the high beam source 72 is deflected and bundled by the ancillary optics 36, which in the present case are catadioptric optics. High beam source 72 and front lens 36 are located in the vertical direction above the uppermost surface of the depression and are designed not to direct the light onto the surface and / or an edge of the diaphragm combination 38, which has a mirrored surface. For this purpose, the diaphragm combination 38 has a depression 40 in each of the high beam channels 86A, 86B, 86C, 86D so that the high beam can pass through the diaphragm combination 38 without being restricted by the diaphragm.

The light channel-individual focal area of the ancillary optics 36 lies in the light path in front of the diaphragm edge 80 of the diaphragm combination 38 facing the light extraction optics 9 and overlaps with the light channel-individual focal area of the lens combination 48. While the light entry surface 50 of the high beam channels of the lens combination 48 is straight and even Is surface, the light exit surface 52 has for each high beam channel 86A, 86B, 86C, 86D a single high beam exit surface 58 with an optically effective curvature, which results in the function of a projection lens. Each channel 86A, 86B, 86C, 86D has exactly one single high beam exit surface 58A, 58B, 58C, 58D available exclusively. In the illustrated, inventive light module 8, the lens combination 48 also has low beam exit surfaces 60, which have already been described above in the description of the low beam channels were. The high beam and low beam exit surfaces 58 and 60 are arranged alternately next to one another. The surfaces 58 of the lens combination 48 are also preferably slightly curved or not curved at all, so that they resemble or resemble a vertically oriented cylinder.

The light propagating in the high beam channels 86A, 86B, 86C, 86D passes through its respective associated part of the lens combination 48. The high beam exit surfaces 58 of the lens combination 48 are shaped so that they focus more horizontally than vertically. This contributes to the desired compactness of the light module 8. Due to the small horizontal space requirement, the semiconductor light sources 70 can be arranged compactly next to one another and / or offset, so that two semiconductor light sources 70 adjacent to one another are separated from one another by an empty space between them.

The light emanating from the high beam sources 72 then hits the partial optics 9B. The partial optics 9B here has the shape of a cylinder lens, the cylinder axis of which in the present embodiment according to the invention is a horizontal line perpendicular to the main emission direction of the light module. In this cylinder lens, the light is bundled, preferably in the vertical direction. The light leaving the cylinder lens generates the high beam distribution that complies with the rules.

In the Figure 11 a comparison of the four low beam channels 84 and the four high beam channels 86 is shown, with point light sources being selected as low beam sources 74 and high beam sources 72 for reasons of clarity. It is thus clearly shown that the low beam attachment optics 34 and the High beam attachment optics 36 have different focal areas. The focal area 88 of the low-beam headlight optics 34 is located near the front edge 80 of the diaphragm combination 38, the focal area 90 of the high-beam headlight optics 36, on the other hand, lies between the front-end optics combination 30 and the front edge 80 of the diaphragm combination 38. This means that the overall magnification of the light module 8 for the high-beam light channels 86 can be made smaller are considered for the low beam channels 84.

This is advantageous because the low beam and high beam distributions have different requirements in terms of width, height and maximum illuminance. While a low beam distribution typically has a maximum width of 100 ° and a maximum height of 20 °, a high beam distribution typically has a smaller width of a maximum of 50 ° and a smaller height of a maximum of 10 °. The ratio of the width of the low beam to the width of the high beam and the height of the low beam to the height of the high beam is both around 2: 1. There are also different requirements for maximum illuminance. While maximum illuminance levels of the order of magnitude of 50 lx on a wall 25 m away are typical for a low beam, it is 100 lx for a high beam. The ratio of the illuminance of the low beam to the high beam therefore corresponds to a ratio of 1: 2. Both the proportions of height and width and of the maximum illuminance levels therefore require a lower magnification for the high beam channels 86.

This can be achieved by the structure described. The total magnification is determined from the product of the magnification through the ancillary optics 30 and the magnification through the lens combination 48. The magnification of the ancillary optics 30 is given by the ratio of Image distance to object distance, where the object is a semiconductor light source 70. In the embodiment described, the object distance (distance between the semiconductor light source and the optical attachment) is selected to be approximately the same for all parts of the optical attachment combination 30. In the high beam channels 86, however, the image range of the high beam attachment optics 36 is selected to be smaller than the image range of the low beam attachment optics 34. The magnification by the high beam attachment optics 36 is therefore lower. The shorter image distance inevitably creates a greater distance between the intermediate image surface and the cylinder lens. As a result, the high beam exit surface 58 of the lens combination 48 can be designed so that the total focal length of the lens combination 48 in the high beam channels 86 is greater than in the low beam channels 84. Since the image distance for light channels 84 and 86 is the same (in the example shown, 25 m) thus the magnification in the high beam channels 86 is also smaller than in the low beam channels 84.

Figure 12 shows the beam paths of the two daytime running light channels 82. In detail, each of the two channels has the following elements: A daytime running light source 76 consisting of a semiconductor light source, a daytime running light attachment lens 32 and a structured disk 9A as part of the light extraction lens 9.

Light which is generated by the daytime running light source 76 is deflected and bundled by the ancillary optics 32, in the present case a catadioptric optic. The light is directed in the direction of the structured pane, which serves as further partial optics 9A of light decoupling optics 9. The pane here has a structure which scatters the light into larger angular ranges in order to distribute daytime running lights and / or position light produce. This can be a pillow structure, for example. Light is preferably scattered in the same way on each part of the structured pane, so that a uniform, bright illumination of the pane results.

The daytime running light channels 82 can alternatively or additionally also be used as a channel for a flashing light. It is advantageous to use yellow semiconductor light sources for this, especially if the channel is to be used in parallel for daytime running lights / position lights. However, it is also possible to use white semiconductor light sources and to color parts of the ancillary optics combination 30 and / or parts of the structured pane yellow. In order to use the channel for daytime running lights and indicators in parallel, a white and a yellow LED can be used next to each other, or an RGB LED can be used, which can be switched white and yellow.

In the Figure 13 a side view of a light module 8 with drawn-in beam paths of a daytime running light channel 82, a low beam channel 84 and a high beam channel 86 is shown.

The semiconductor light sources 72, 74, 76 are all arranged in one plane, to which the front lens combination 30 consisting of daytime running light front lens 32, low beam front lens 34 and high beam front lens 36 is connected.

The daytime running light channel 82 is arranged above the other two channels. It does not pass through the diaphragm combination 38 and the lens combination 48, but instead the light hits the structured lens directly after leaving the daytime running light attachment optics 32 Disc.

Low beam channel 84 and high beam channel 86, on the other hand, after their respective ancillary optics 34 and 36, both pass through the diaphragm combination 38 and then the lens combination 48. Ultimately, both meet their part of the light decoupling optics 9, which is implemented by a cylindrical lens.
Figure 14 shows a further comparison of the beam paths of the daytime running light channels 82, low beam channels 84 and high beam channels 86 within a lighting module 8 according to the invention in a three-dimensional view. The daytime running light channels 82, which are arranged above the low-beam light channels 84 and high-beam light channels 86, hit the structured pane, which forms part of the light extraction optics 9, directly after leaving the front lens combination 30.

Low beam channels 84 and high beam channels 86 are arranged alternately next to one another. Both pass through the diaphragm combination 38 and the lens combination 48 after leaving the attachment optics combination 30. The light rays from these channels leave the light module 8 via the part of the light decoupling optics 9, which is a cylindrical lens.
The Figures 13 and 14th clearly show that the light module can easily be divided in terms of its light functions into a lower part (headlight functions such as low beam and high beam generation) and an upper part (signal light functions such as flashing light, daytime running light, position light, ...), whereby this functional separation is possible is accompanied by a structural separation.

Claims (13)

1. Light module (8) for a motor vehicle headlamp with at least two semiconductor light sources (72, 74, 76), a respective individual optical attachment (32, 34, 36) for each semiconductor light source (72, 74, 76), a light extraction optics (9) having at least one partial optical system (9B) and a screen(38) arranged between the optical attachment (32, 34, 36) and the extraction optics (9), wherein the light module (8) is designed to be able to generate at least two different regulation-compliant light distributions, either individually or in any combination, wherein a lens combination (48) is arranged between the light extraction optics (9) and the screen (38), which is illuminated by at least one of the two semiconductor light sources (72, 74, 76) and from which light from this semiconductor light source emerges in a cone of light, the lens combination (48) having a different refractive power in two spatial directions perpendicular to one another and to the main direction of propagation of the light emitted by the light module (8), and the light extraction optics (9) which is arranged in the light cone of the lens combination (48), has a different refractive power in two spatial directions perpendicular to each other and to the main direction of propagation of the light emitted by the light module (8), wherein the refractive power of the light extraction optics (9) is greater in the spatial direction in which the lens combination (48) has the smaller of its two refractive powers, and wherein the lens combination (48) is arranged closer to the screen (38) than to the light extraction optics (9), wherein the light module (8) has at least one low beam channel (84) and at least one high beam channel (86), each low beam channel (84) having a light source (74), an optical attachment (34) collecting and focusing light from this light source, an elevation (42) of the screen (38), and a projection lens system, which consists of a lenticular portion of the lens combination (48) or an individual lens of the lens combination (48) and the light extraction optics, wherein each portion of the lens combination (48) or each individual lens of the lens combination (48) is arranged in the light cone of exactly one optical attachment (34), characterized in that an attachment optic-side focal length of the projection lens system is greater in each high beam channel (86) than in each low beam channel (84), and in that at least two low beam channels have a different screen shape of the screen (38).
2. Light module according to one of the preceding claims, characterised in that the lens combination (48) consists of a number of individual lenses, each of which is illuminated by exactly one of the attachment optics (34, 36) with light from one of the light sources (74, 76), wherein the individual lenses are arranged in a row extending transversely to the main light propagation direction and wherein the partial optics (9B) of the light extraction optics (9) consists of a single lens associated with all individual lenses.
3. Light module (8) according to one of the preceding claims, characterised in that the spatial directions in which the light extraction optics (9) and the lens combination (48) have different refractive power are a horizontal and a vertical spatial direction when the light module is used as intended.
4. Light module (8) according to one of the preceding claims, characterised in that the light emitted by the light module is a regulation-compliant low beam and high beam and: daytime running light and/or position light and/or flashing light and/or cornering light and/or motorway light and/or town light and/or partial high beam and/or marker light.
5. Light module (8) according to one of the preceding claims, characterised in that the light extraction optics (9) has a further partial optics (9A) and that the optical attachment (32) of at least one of the semiconductor light sources (72) is set up and arranged to direct light of this semiconductor light source (72) past the lens combination (48) onto the further partial optics (9A) and that the further partial optics (9A) is arranged to produce a light distribution which is different from the light distributions of the light propagated by the lens combination (48).
6. Light module (8) according to one of the preceding claims, characterised in that the semiconductor light sources (72, 74, 76) are arranged in a matrix-like manner and wherein individual or several rows of semiconductor light sources (72, 74, 76) are set up to jointly generate at least one regulation compliant light distribution in each case.
7. Light module (8) according to one of the preceding claims, characterized in that the screen (38) is a screen combination of at least one elevation (42) and at least one depression (40), the elevation (42) being arranged in the light path of a low beamlight source (74) and the depression (40) being arranged in the light path of a high beam source (72).
8. light module (8) according to claim 7, characterised in that some of the elevations (42) have a step (44) for generating a step in a light/dark boundary in the low beam light distribution.
9. Light module (8) according to one of the preceding claims, characterised in that an edge (80) of the screen (38) facing the light extraction optics (9) is arranged in a focal region of the attachment optics and in a focal region (88) of a projection lens system consisting of the lens combination (48) and the light extraction optics (9) .
10. Light module (8) according to one of the preceding claims, characterised in that at least a lenticular section of the lens combination (48) or an individual lens of the lens combination (48) is arranged in the light cone of exactly one optical attachment (34, 36).
11. Light module (8) according to one of the preceding claims, characterised in that the first partial optics(9B) of the light extraction optics(9) is a cylindrical lens.
12. Light module (8) according to one of the preceding claims, characterised in that the additional partial optics(9A) of the light extraction optics(9) is a structured lens and/or a cushion optics and/or made of a volume-diffusing material, and/or in that a part of the light module (8) assigned to the partial optics (9A), which is set up to produce a regulation-compliant daytime running light distribution, is also set up to produce a regulation-compliant flashing light distribution.
13. Light module (8) according to one of the previous claims, characterised in that the light extraction optics (9) is a one-piece component.

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