EP3492809B1 - Vehicle headlight and method for adjusting a light source and an adaptor lens - Google Patents

Description

The invention relates to a vehicle headlight, comprising a light source and a front lens system, the light source being set up to emit light through the front lens system and the front lens system being set up to bundle or shape the light, and to fix the light source on a support provided in the vehicle headlight , in which a bore is provided for receiving at least one connecting means, and at least one spacer element is arranged on the carrier in each case on a support surface, the at least one spacer element having a height normal to the support surface, and a retaining bracket is arranged on the at least one spacer element is, the retaining bracket is fixedly connected to the optical attachment and each has an opening which is provided for receiving the at least one connecting means, and the at least one connecting means which respectively extends along an axis and for connecting the Retaining bracket is provided with the carrier and is used for this purpose in the respective opening and in the respective bore. The invention also relates to a method for assembling and adjusting a light source and a front lens system of a vehicle headlight, the light source being set up to emit light through the front lens system and the front lens system being set up to bundle or shape the light.

When assembling optical components of a vehicle headlight, it is necessary to adjust these components to one another in order to achieve a desired optical function of the vehicle headlight. In addition to the precise alignment of the optical components to one another, the adjustment requires simple handling during the assembly process. In addition, it is necessary for the adjustment to be permanent and to be particularly robust with regard to environmental influences, such as temperature fluctuations or vibrations, during the life cycle of the vehicle headlight. Current designs often have the disadvantage that the design is complex, assembly is expensive, or the adjustment can become loose over time or after excessive use and expensive re-adjustment may be required.

From the document US 2014/168996 a vehicle headlight with the features of the preamble of claim 1 is known.

It is an object of the invention to provide a method and a vehicle headlight of the type mentioned at the outset with which the disadvantages of the prior art are overcome.

The object is achieved by a vehicle headlight of the type mentioned at the outset, which, in a first position of the holding bracket, in which the at least one connecting means is inserted into the opening but is not fixed, normalizes the holding bracket in one plane with respect to the at least one connecting means within the opening can be moved to the axis in order to allow an alignment of the attachment optics attached to the holding bracket with respect to the light source attached to the support, and the at least one spacer element can be pressed together by means of the at least one connecting means through the holding bracket and the support, the Height of the at least one spacer element is reduced in order to align the light source and the front optics with respect to one another in the direction of the axis and a fixed, second position of the holding bracket is achieved.

It is favorable if the modulus of elasticity of the at least one spacer element is smaller than the modulus of elasticity of the holding bracket and / or the carrier. It is thereby achieved that the at least one spacer element is more easily compressible when the holding bracket and / or the carrier is pressed on.

It is particularly advantageous if the elastic modulus of the at least one spacer element is less than 80 kN / mm ² , preferably less than 30 kN / mm ² , particularly preferably less than 4 kN / mm ² and greater than 1 kN / mm ² . It is thereby achieved that the at least one spacer element is easier to compress.

It is also particularly favorable if the yield point of the at least one spacer element is less than 100 kN / mm ² , preferably less than 80 kN / mm ² and greater than 10 kN / mm ² , particularly preferably less than 70 kN / mm ² and larger than 20 kN / mm ² . It is thereby achieved that the at least one spacer element is easier to compress.

In a further development of the invention, the limit values mentioned for the modulus of elasticity and the yield point can be combined to form an even better one To obtain coordination of the material properties of the at least one spacer element, which are particularly advantageous for the arrangement according to the invention.

In a further development of the invention, the vehicle headlight comprises at least two spacer elements and at least two connecting means, the at least two spacer elements being arranged in such a way that the holding bracket can be adjusted with respect to the carrier, in which the at least two spacer elements each have a different height in the adjusted position exhibit. This ensures that assembly influences, such as those of the light sources or the front optics, can be easily compensated for.

It is advantageous if a circuit board is arranged between the light source and the carrier, on which the light source is attached. As a result, the light source can easily be contacted electrically and mechanically connected to the carrier. The light source can comprise a plurality of lighting elements, for example in the form of semiconductor lighting elements such as LEDs or laser diodes, which are mounted on a common or a plurality of printed circuit boards or circuit carriers. Printed conductors and other electronic components for controlling the light source can be included in the circuit board. If several lighting elements are used, it is often necessary to provide respective optical lens elements, for example in the form of elongated optical light guides or optical converging lenses. The front lens, which can be formed from several optical elements, is attached to a common holder.

Furthermore, it is advantageous if a heat sink is arranged on the carrier, or the carrier itself has cooling fins or cooling pins, and the at least one light source is fastened to the carrier. In this way, the power loss that arises at the light source during operation can be dissipated. The connection of the carrier to the heat sink creates a mechanically stable and resilient deformation, which is taken into account by the adjustable connection between the holder and the carrier.

Alternatively, a circuit board can be arranged between the light source and the heat sink, on which the light source is attached. As mentioned above, several lighting elements, further electronic components and conductor tracks can be included in the circuit board.

In a favorable embodiment of the invention, the carrier has a through opening through which the light source protrudes.

It is advantageous if the carrier further has at least one cavity, each with a depth, which is provided for receiving the at least one spacer element and is shaped essentially complementarily to the outer contour of the at least one spacer element, the height of the at least one spacer element being greater than that Depth of at least one cavity. This ensures that the spacer element is already held firmly in one position before assembly.

In addition, it is advantageous if a layer is applied between the at least one spacer element and the carrier and / or between the at least one spacer element and the retaining bracket and / or between the at least one connecting means and the carrier, which layer contains an adhesive, which preferably contains a fluid Has shape. The adhesive ensures that the arrangement is fixed after an adjustment and is resistant to the connection being loosened independently. In the automotive environment, for example, undesirable temperature influences can occur, which can lead to a disadjustment of the arrangement.

It is also advantageous if the adhesive is embedded in a number of microcapsules and is preferably carried by a fluid carrier material in which the number of microcapsules is embedded. By using microencapsulated adhesive, for example a one-component (1K) or two-component adhesive (2K), it can be achieved that more assembly time is available for the adjustment of the arrangement than when using a conventional adhesive, which quickly after application of the adhesive starts to harden, making adjustment difficult. Through a previously mentioned cavity, it can also be achieved that when the at least one spacer element is compressed in the axial direction of the at least one connecting means, the at least one spacer element presses against the wall of the cavity and thus causes the microcapsules to burst, so that the adhesive can escape and for example can mix with the hardener of the 2-component adhesive and harden.

This can be achieved if the number of microcapsules at least partially bursts and the embedded adhesive is released due to the at least one connecting means being non-positively connected to the support bracket.

For a simple implementation, it is favorable if the at least one spacer element each has a spacer element opening and preferably has a torus shape, and the at least one connecting means is guided through the spacer element opening.

It is advantageous if the inside diameter of the opening of the holding bracket is larger than the outside diameter of the connecting means. In other words, the retaining bracket should be movable around the connecting means for adjustment if the arrangement has not yet been fixed.

Furthermore, it is favorable for a simple implementation if the at least one connecting means is a screw, and preferably the bore of the carrier has a thread which is set up to come into engagement with the at least one connecting means.

In addition, it is advantageous if the carrier comprises at least one pinch rib, which is set up to engage the holding bracket in the adjusted state. The result of this is that the arrangement can be adjusted in the plane normal to the axial direction of the at least one connecting means, and when the force acting through the at least one connecting means is increased, the arrangement is fixed in the plane before an adjustment in the axial direction of the at least one Lanyard is done. This sequence noticeably facilitates the adjustment process.

• Anordnen und Fixieren der Lichtquelle im Bereich einer Auflagefläche des Trägers, bei welchem eine Bohrung zur Aufnahme zumindest eines Verbindungsmittels, das sich in einer Längsrichtung erstreckt und in Richtung der Längserstreckung eine Achse aufweist, vorgesehen ist,
• Anordnen zumindest eines Distanzelements auf dem Träger, und eines Haltebügels auf dem Distanzelement, wobei der Haltebügel mit der Vorsatzoptik fest verbunden ist und zumindest eine Öffnung aufweist, die zur Aufnahme des zumindest einen Verbindungsmittels vorgesehen ist,
• Einsetzen des zumindest einen Verbindungsmittels in die jeweilige Öffnung und in die jeweilige Bohrung,
• Herstellen eines Anfangs-Justier-Zustands durch Ausrichten der Vorsatzoptik mit der Lichtquelle in einer XY-Ebene, welche normal zur Achse definiert ist,
• Festlegen des Anfangs-Justier-Zustands in der XY-Ebene durch Verbinden des Trägers und des Haltebügels durch Ausüben einer ersten Kraft mittels des zumindest einen Verbindungsmittels, wobei ein erster Justierzustand mit einer ersten Justierhöhe erreicht wird,
• Herstellen eines dritten Justier-Zustandes in der XY-Ebene und in Richtung der Achse durch Ausüben einer dritten Kraft mittels der Verbindungsmittel zwischen dem Träger und dem Haltebügel, wobei eine dritte Justier-Höhe erreicht wird.

The task is also solved by a corresponding method. The method relates to the assembly and adjustment of a light source and a front lens system of a vehicle headlight to one another, the front lens system being set up to bundle or shape the light emitted by the light source, the vehicle headlight further comprising a carrier and a holding bracket, and the following method steps being carried out :

• Arranging and fixing the light source in the area of a support surface of the carrier, in which a bore for receiving at least one connecting means, which is located in extends in a longitudinal direction and has an axis in the direction of the longitudinal extent,
• Arranging at least one spacer element on the carrier, and a retaining bracket on the spacer element, the retaining bracket being firmly connected to the front lens system and having at least one opening which is provided for receiving the at least one connecting means,
• Inserting the at least one connecting means into the respective opening and into the respective bore,
• Establishing an initial adjustment state by aligning the front lens system with the light source in an XY plane which is defined normal to the axis,
• Determining the initial adjustment state in the XY plane by connecting the carrier and the holding bracket by exerting a first force by means of the at least one connecting means, a first adjustment state being achieved with a first adjustment height,
• Establishing a third adjustment state in the XY plane and in the direction of the axis by exerting a third force by means of the connecting means between the carrier and the holding bracket, a third adjustment height being achieved.

The sequence of the individual method steps can be adapted as required for different embodiments according to the respective requirements. However, the method should preferably be carried out in the sequence mentioned.

It is achieved by the method according to the invention that at least one light source and at least one front lens system of a vehicle headlight can be installed and adjusted to one another in a particularly simple manner.

In a further development of the invention, the limit values mentioned for the modulus of elasticity and the yield point can be combined in order to obtain an even better coordination of the material properties of the at least one spacer element, which are particularly advantageous for the arrangement according to the invention.

• Herstellen eines zweiten Justier-Zustandes, wobei der Klebstoff durch Ausüben einer zweiten Kraft mittels der Verbindungsmittel zwischen dem Träger und dem Haltebügel aktiviert wird und eine zweite Justier-Höhe erreicht wird, und

nach dem Schritt des Herstellens des dritten Justier-Zustands folgender Schritt ausgeführt ist:

• Festlegen des dritten Justier-Zustands in der XY-Ebene und in Richtung der Achse in der dritten Justierhöhe durch Aushärten des aktivierten Klebstoffs.

It is advantageous if an activatable adhesive is applied to the outer surface of the at least one spacer element before the step of inserting the at least one connecting means, and
the following step is carried out before the step of establishing the third adjustment state:

• Producing a second adjustment state, the adhesive being activated by exerting a second force by means of the connecting means between the carrier and the holding bracket and a second adjustment height being reached, and

after the step of establishing the third adjustment state, the following step is carried out:

• Definition of the third adjustment state in the XY plane and in the direction of the axis at the third adjustment height by curing the activated adhesive.

By using an adhesive, it can be achieved that the entire arrangement remains fixed over a long period of time even after an adjustment has been made during operation of the vehicle, during which mechanical and thermal influences, for example, can adversely affect the adjustment of the arrangement.

In the unassembled arrangement, the adhesive is in an activatable form. For example, a two-component (2K) adhesive is inactive until the adhesive and the hardener of the 2K adhesive come into contact with each other. Alternatively, a one-component (1-component) adhesive is inactive until the 1-component adhesive can react with the surrounding air and harden. If the method provides for the use of an activatable adhesive, the person who carries out the adjustment and assembly has sufficient time for the adjustment and assembly. Only after the adhesive has been activated must the adjustment be completed quickly so that the adhesive connection can be cured reliably.

It is also advantageous if the adhesive wets the outer surface of the spacer element.

In a preferred further development of the invention, it is advantageous if a layer is applied between the at least one spacer element and the carrier and / or between the at least one spacer element and the retaining bracket and / or between the at least one connecting means and the carrier, which layer can be activated Contains adhesive, which preferably has a fluid form. This allows the entire connection to be permanently fixed.

Furthermore, it is expedient if the adhesive is embedded in a number of microcapsules and is preferably carried by a fluid carrier material in which the number of microcapsules is embedded, and the number of microcapsules bursts at least partially when a mechanical force acts on the microcapsules and releases the embedded adhesive. This enables simple implementation. The mechanical force at which the microcapsules burst can be used to measure all the forces which have a function and function in the adjustment and assembly of the entire arrangement.

It also applies to the adjustment and assembly method that it is advantageous if the modulus of elasticity of the at least one spacer element is smaller than the modulus of elasticity of the holding bracket and / or the carrier.

Furthermore, it is also advantageous for the method if the modulus of elasticity of the at least one spacer element is less than 80 kN / mm ² , preferably less than 30 kN / mm ² , particularly preferably less than 4 kN / mm ² and greater than 1 kN / mm ² .

It is also advantageous for the method if the yield point of the at least one spacer element is less than 100 kN / mm ² , preferably less than 80 kN / mm ² and greater than 10 kN / mm ² , particularly preferably less than 70 kN / mm ² and greater than 20 kN / mm ² .

In a further development of the invention, the limit values mentioned for the modulus of elasticity and the yield point can be combined in order to obtain an even better coordination of the material properties of the at least one spacer element, which are particularly advantageous for the method according to the invention.

Fig.1

eine Explosionsdarstellung eines Ausführungsbeispiels eines Fahrzeugscheinwerfers, der nach dem erfindungsgemäßen Justierverfahren zusammengesetzt werden kann,

Fig. 2

eine vergrößerten Ausschnitt der Fig. 1, der den Anfangszustand des erfindungsgemäßen Justierverfahrens zeigt,

Fig.3

einen ersten Verfahrensschritt mit einem Anfangs-Justier-Zustand, in dem die Anordnung zusammengesetzt ist und eine erste Justierung erfolgt,

Fig. 4

einen weiteren Verfahrensschritt mit einem ersten Justier-Zustand, in dem die Justierung festgelegt wird,

Fig. 5

einen anschließenden Verfahrensschritt mit einem zweiten Justier-Zustand, in dem der Kleber für die Justierung aktiviert wird,

Fig.6

einen letzten Verfahrensschritt mit einem dritten Justier-Zustand,

Fig.7

eine Querschnittsansicht eines weiteren Ausführungsbeispiels, in dem der Träger einen zusätzlichen Kühlkörper umfasst.

The invention and its advantages are described in more detail below with reference to a non-restrictive exemplary embodiment, which is illustrated in the accompanying drawings. The drawings show in:

Fig. 1

2 shows an exploded view of an exemplary embodiment of a vehicle headlight that can be assembled using the adjustment method according to the invention,

Fig. 2

an enlarged section of the Fig. 1 which shows the initial state of the adjustment method according to the invention,

Fig. 3

a first method step with an initial adjustment state in which the arrangement is assembled and a first adjustment takes place,

Fig. 4

a further method step with a first adjustment state, in which the adjustment is determined,

Fig. 5

a subsequent process step with a second adjustment state in which the adhesive for the adjustment is activated,

Fig. 6

a last method step with a third adjustment state,

Fig. 7

a cross-sectional view of a further embodiment in which the carrier comprises an additional heat sink.

With reference to 1 to 7 Embodiments of the invention will now be explained in more detail. In particular, parts which are important for the invention are shown in a headlight, it being clear that a headlight also contains many other parts, not shown, which enable sensible use in a motor vehicle, such as in particular a car or motorcycle. For the sake of clarity, cooling devices for components, control electronics, further optical elements, mechanical adjustment devices or brackets are not shown, for example.

The 1 to 3 show a vehicle headlight 1, comprising a light source 2 and a front lens 3, the light source 2 being set up to emit light through the front lens 3 and to bundle or shape it.

In Fig. 1 an XYZ coordinate system is also specified, on the basis of which the arrangement according to the invention is to be adjusted.

The light source 2 is fastened on a support 10 provided in the vehicle headlight 1, in each of which a bore 12 and 13 is provided for receiving two connecting means 20 and 21.

The light source 2 can be formed from several optoelectronic components, preferably from LEDs or laser diodes. Several lighting elements of the light source 2 can be used for different light functions of the vehicle headlight 1 and can be operated differently in this sense.

A circuit board 4 is arranged between the light source 2 and the carrier 10, on which the light source 2 is fastened. Contact connection surfaces and conductor tracks for electrically contacting the light source 2 can be located on the circuit board (not shown). The light source 2 is preferably connected electrically and mechanically to the contact pads by soldering or gluing.

The connecting means 20, 21 are screws in this exemplary embodiment, and the bores 12, 13 of the carrier 10 each have an internal thread which is set up to engage with the two connecting means 20, 21, which each comprise a complementary external thread. In principle, the connecting means can also be another suitable element, such as a rivet. Alternatively, the connecting means 20, 21 can also be threaded rods, for example, which are adjustably limited on both sides by nuts.

In addition, the carrier 10 comprises a plurality of crush ribs 70, which are set up to engage the holding bracket 40 in an adjusted state. The squeezing ribs 70 are not absolutely necessary, but they facilitate the subsequent adjustment of the arrangement in that an alignment in an XY plane, which is normal to the longitudinal extent of the connecting means 20, 21, can be fixed in a first step in that the lateral friction coefficient can be increased by the pinch ribs 70. The crush ribs 70 may be formed from needle-like, circular or line-shaped elements and may be formed from one or more such elements.

Furthermore, two spacer elements 30, 31 are each arranged on the carrier 10 in the region of a support surface 11, the two spacer elements 30, 31 each having heights 35, 36 normal to the support surface 11.

The two spacer elements 30, 31 are arranged such that an adjustment of the holding bracket 40 with respect to the carrier 10 can be achieved, in which the two spacer elements 30 and 31 can each have a different height 35 and 36 in an adjusted position.

The carrier 10 also has two cavities 14 and 15, each with a depth 16 and 17, which are provided for receiving a spacer element 30, 31 and are essentially complementary to the outer contour of the at least one spacer element 30, 31, the height 35 , 36 of the two spacer elements 30 and 31 is greater than the depth 16 and 17 of the two cavities 14 and 15. The depth 16 and 17 of the cavities 14 and 15 is preferably the same size.

The cavity can alternatively also be designed as a blind hole which does not run completely through the carrier and has a thread for receiving a connecting means in the form of a screw.

In principle, other shapes for the cavity are also possible. It is advantageous if the shape of the cavity corresponds to the shape of the spacer element that is to be inserted into the cavity.

In some embodiments, it can be advantageous if a spacer element 30, 31 consists of several spacer element units, which can be stacked on top of one another, for example, within the associated cavity.

Furthermore, a holding bracket 40 is arranged on the two spacer elements 30, 31, the holding bracket 40 being fixedly connected to the optical attachment 3 and each having an opening 41, 42 which is provided for receiving the two connecting means 20, 21.

The connecting means 20, 21, which each extend along an axis 22, 23 and are provided for connecting the holding bracket 40 to the carrier 10, are inserted into the respective opening 41, 42 and in the respective bore 12, 13 for this purpose.

The holes 12 and 13 each have threads 18, 19 to receive the thread of the respective screw 20, 21.

Referring to 3 to 6 the adjustment of the arrangement will now be described in more detail, wherein only one connecting means 20 from the Fig. 1 with the associated bore 12, the thread 18, the cavity 14 and the axis 22 is shown. Of course, the same applies to the connecting means 21 with the associated bore 13, the thread 19, the cavity 15 and the axis 23, which in the Fig. 1 are recognizable.

In a first position of the holding bracket 40, in which the two connecting means 20, 21 are inserted into the opening 41, 42 but are not fixed, the holding bracket 40 can be normal with respect to the two connecting means 20 and 21 within the openings 41 and 42 in one plane are moved to the axes 22 and 23 in order to enable an alignment in the plane of the attachment optics 3 attached to the holding bracket 40 with respect to the light source 2 attached to the carrier 10. In this example, the adjustment level is the XY level of the Fig. 1 , which is also shown in the other figures.

The adjustment in the XY plane can take place within a range which is limited by the distance between the outer diameter 25 of the connecting means 20, 21 and the inner diameter 45 of the opening 41, 42 of the holding bracket 40. In other words, the holding bracket 40 is movable within its opening 41, 42 around the connecting means 20, 21 in an unfixed but assembled state, since the inner diameter 45 of the opening 41, 42 is larger than the outer diameter 25 of the connecting means 20, 21.

The two spacer elements 30, 31 can be pressed together by means of the two connecting means 20, 21 through the holding bracket 40 and the carrier 10, the height 35, 36 of the two spacer elements 30, 31 being reduced by the light source 2 and the front lens 3 align in the direction of axes 22, 23 and a fixed, second position of the bracket 40 is reached.

The two spacer elements 30, 31 can be covered on their surface by a layer which comprises an adhesive 51 in fluid form, which is embedded in a number of microcapsules 50 in a carrier material of the layer. The microcapsules 50 are carried by an initially fluid carrier material, which dries after application to the spacer elements 30, 31 and thereby facilitates the assembly and adjustment of the arrangement.

The adhesive 51 can have a fluid form, for example liquid, pasty or gel-like. A quantity of small drops of the adhesive 51 is enclosed in a shell, which form microbeads 50.

When a force is exerted on the shell of the microbeads 50, the microbeads 50 can burst and the enclosed adhesive 51 can escape. The adhesive can harden through exposure to ambient air. Alternatively, the adhesive 51 can be formed from two adhesive components of a two-component adhesive, which can be contained separately in different microbeads 50 and which only react by mutual contact after the shell of the microbeads 50 has burst. As a result, the two adhesive components can mix and the adhesive mixture can harden.

Due to a higher force effect, that is to say by a force-fit connection of the carrier 10 to the holding bracket 40 by the two connecting means 20, 21, the number of microcapsules 50 can at least partially burst and release the embedded adhesive 51.

The two spacer elements 30, 31 each have a spacer element opening and are shaped like a torus. The two connecting means 20, 21 are guided through the spacer opening. In this context, a torus shape means that the shape can also be that of a truncated cone and it is not relevant if, for example, edges are not formed exactly. The opening 41, 42 of the at least one holding bracket 40 has a cross section that is smaller than the cavity 14, 15. Furthermore, the inside diameter 45 of the opening 41, 42 is larger than the outside diameter 25 of the connecting means 20, 21. This can be achieved that the bracket 40 is adjustable in a plane that is transverse to the axis 22, 23, as long as the arrangement is not yet by Connecting means 20, 21 is fixed or has reached a positive connection, as a result of which the frictional forces in the event of a lateral movement of the holding bracket 40 with respect to the spacer element 30, 31 or the carrier 10 prevent further lateral movement and thus achieve a first adjustment.

An acting force 81 is transmitted from the spacer elements 30, 31 to the microbeads 50 and the microbeads 50 burst from a predetermined strength of the force. It is clear that the microbeads 50 which are located on the end faces of the spacer element 30, 31 are more likely to burst. Due to the compression of the spacer elements 30, 31 by the acting force 81, however, it is also possible that the spacer elements 30, 31 expand laterally and thus also micro beads 50 located on the side burst and the adhesive 51 can escape. This effect can be improved, for example, in that the spacer elements 30, 31 each have a tapered shape of a truncated cone on their outer surfaces, and the lateral microbeads 51 are thus increasingly exposed to the pressing force.

It is clear that not all microbeads 50 have to have burst in order to achieve a sufficient adhesive effect due to the leaked adhesive 51 of the burst microbeads 50.

The adhesive 51 is known from the technique of thread locking by gluing. Microencapsulated adhesives are a dry, non-slip, paint-like coating. The adhesive begins to harden immediately after the casing has been broken open. Since today's products are fast curing systems, measurable results are achieved after only 10-15 minutes. The curing is completely finished after 24 hours, but can be accelerated by applying temperature. After curing, the desired fixing or securing effect is completely achieved, and an additional sealing effect is achieved at the same time.

Depending on the application, it may be necessary to use several such arrangements, each of which comprises the above-described supports 10, screws 20, spacers 30 and brackets 40, for fastening and adjustment.

• Anordnen und Fixieren der Lichtquelle 2 im Bereich einer Auflagefläche 11 des Trägers 10 , bei welchem eine Bohrung 12, 13 zur Aufnahme von Verbindungsmitteln 20 und 21, beispielsweise Schrauben, welche sich jeweils in einer Längsrichtung erstrecken und in Richtung der Längserstreckung jeweils eine Achse 22, 23 aufweisen, vorgesehen ist,
  • Anordnen von Distanzelementen 30 und 31 auf dem Träger 10 und eines Haltebügels 40 auf den Distanzelementen 30 und 31, wobei der Haltebügel 40 mit der Vorsatzoptik 3 fest verbunden ist und jeweils eine Öffnung 41 und 42 aufweist, welche zur Aufnahme der Verbindungsmittel 20 und 21 vorgesehen ist,
  • Einsetzen der Verbindungsmittel 20, 21 in die jeweilige Öffnung 41, 42 und in die jeweilige Bohrung 12 und 13, wobei auf der Außenoberfläche der Distanzelemente 30, 31 und/ oder der Verbindungsmittel 20, 21 ein aktivierbarer Klebstoff 51 aufgebracht ist,
  • Herstellen eines Anfangs-Justier-Zustands mit einer Anfangs-Justier-Höhe 60 durch Ausrichten der Vorsatzoptik 3 zu der Lichtquelle 2 in einer XY-Ebene, welche normal zur Achse 22, 23 definiert ist,
  • Festlegen des Anfangs-Justier-Zustands in der XY-Ebene durch Verbinden des Trägers 10 und des Haltebügels 40 durch Ausüben einer ersten Kraft 80 mittels des zumindest einen Verbindungsmittels 20, 21, wobei ein erster Justierzustand mit einer ersten Justierhöhe 61 erreicht wird,
  • Herstellen eines zweiten Justier-Zustandes, wobei der Klebstoff 51 durch Ausüben einer zweiten Kraft 81 mittels der Verbindungsmittel 20, 21 zwischen dem Träger 10 und dem Haltebügel 40 aktiviert wird und eine zweite Justier-Höhe 62 erreicht wird,
  • Herstellen eines dritten Justier-Zustandes in der XY-Ebene und in Richtung der Achse 22, 23 durch Ausüben einer dritten Kraft 82 mittels der Verbindungsmittel 20, 21 zwischen dem Träger 10 und dem Haltebügel 40, wobei eine dritte Justier-Höhe 63 erreicht wird,
  • Festlegen des dritten Justier-Zustands in der XY-Ebene und in Richtung der Achse 22, 23 in der dritten Justierhöhe (63) durch Aushärten des aktivierten Klebstoffs 51.

In summary, what has been said before, as in the Fig. 1 and 3 to 6 shown, the method for mounting and adjusting a light source 2 and a front lens 3 of a vehicle headlamp 1 to each other, the front lens 3 is set up to bundle or shape the light emitted by the light source 2, the vehicle headlamp 1 further comprising a carrier 10 and one Retaining bracket 40 includes, are described by performing the following method steps:

• Arranging and fixing the light source 2 in the region of a support surface 11 of the carrier 10, in which a bore 12, 13 for receiving connecting means 20 and 21, for example screws, which each extend in a longitudinal direction and an axis 22 in the direction of the longitudinal extent, 23, is provided
  • Arranging spacer elements 30 and 31 on the carrier 10 and a retaining bracket 40 on the spacer elements 30 and 31, the retaining bracket 40 being fixedly connected to the optical attachment 3 and each having an opening 41 and 42, which is provided for receiving the connecting means 20 and 21 is
  • Inserting the connecting means 20, 21 into the respective opening 41, 42 and into the respective bore 12 and 13, an activatable adhesive 51 being applied to the outer surface of the spacer elements 30, 31 and / or the connecting means 20, 21,
  • Establishing an initial adjustment state with an initial adjustment height 60 by aligning the front lens 3 to the light source 2 in an XY plane which is defined normal to the axis 22, 23,
  • Determining the initial adjustment state in the XY plane by connecting the carrier 10 and the holding bracket 40 by exerting a first force 80 by means of the at least one connecting means 20, 21, a first adjustment state being achieved with a first adjustment height 61,
  • Producing a second adjustment state, the adhesive 51 being activated by exerting a second force 81 by means of the connecting means 20, 21 between the carrier 10 and the holding bracket 40 and a second adjustment height 62 being reached,
  • Establishing a third adjustment state in the XY plane and in the direction of the axis 22, 23 by exerting a third force 82 by means of the connecting means 20, 21 between the carrier 10 and the holding bracket 40, a third adjustment height 63 being reached,
  • Determining the third adjustment state in the XY plane and in the direction of the axes 22, 23 in the third adjustment height (63) by curing the activated adhesive 51.

In the Fig. 3 the initial adjustment state is shown with the initial adjustment height 60, which occurs without the action of a force 80 and an adjustment takes place in the XY plane.

In the Fig. 4 the first adjustment state is shown with the first adjustment height 61, which is achieved by the action of the first force 80. The first adjustment state is an intermediate state which serves to prevent the arrangement from slipping in the XY plane by the application of the first force 80, which is caused by that in FIG Fig. 3 step shown was reached.

In the Fig. 5 the second adjustment state is shown with the second adjustment height 62, which is achieved by the action of the second force 81. The second adjustment state is an intermediate state which serves to activate the adhesive 51 by applying the second force 81 by the microcapsules 50 bursting open.

In the Fig. 6 the third adjustment state is shown with the third adjustment height 62, which is achieved by the action of the third force 82. The third adjustment state is a final state which serves to fix the arrangement after the adhesive 51 has hardened.

In this context, it is clear that the adhesive 51 does not have to completely wet all or individual surfaces in order to achieve a fixing effect.

Before the spacer elements 30, 31 are arranged, a layer is applied between the spacer elements 30, 31 and the carrier 10 and / or between the spacer elements 30, 31 and the holding bracket 40 and / or between the connecting means 20, 21 and the carrier 10, which one layer activatable adhesive 51, which preferably has a fluid form.

The adhesive 51 is embedded in a number of microcapsules 50 and is preferably carried by a fluid carrier material in which the number of microcapsules 50 is embedded, and the number of microcapsules 50 at least partially when subjected to a mechanical force which corresponds to the aforementioned second force 81 corresponds in the method, bursts onto the microcapsules 50 and releases the embedded adhesive 51.

The modulus of elasticity of the spacer elements 30, 31 is that it is in each case smaller than the modulus of elasticity of the holding bracket 40 and / or the carrier 10.

The modulus of elasticity of the spacer elements 30, 31 is less than 80 kN / mm ² , for example in the case of aluminum, preferably less than 30 kN / mm ² , particularly preferably less than 4 kN / mm ² and greater than 1 kN / mm ² , for example for plastics.

The yield point of the spacer elements 30, 31 is less than 100 kN / mm ² , for example in the case of aluminum, preferably less than 80 kN / mm ² , for example in the case of plastics, and greater than 10 kN / mm ² , particularly preferably less than 70 kN / mm ² and greater than 20 kN / mm ² .

The material of the spacer elements 30, 31 can be, for example, a plastic, such as polyamide PA, polycarbonate PC, ABS, polypropylene PP, polystyrene PS or special thermoplastics, but also a soft metal such as aluminum.

The material of the carrier 10 can, for example, be a metal such as aluminum, copper or brass, the holding bracket 40 can consist, for example, of plastic such as PC, ABS or PS, or of a metal such as aluminum or an alloy such as brass or steel sheet, the above material properties mentioned are preferably present. A good thermal conductivity of the material of the carrier 10 is advantageous.

The material of the holding bracket 40 can be, for example, a plastic, plastic with a high modulus of elasticity, such as PC or PS, but also a metal, such as aluminum or sheet steel. A high modulus of elasticity of the material is advantageous.

Fig. 7 shows a cross-sectional view of a further embodiment of the invention. A headlight 101 has a carrier 110, which has a separately shaped Heatsink 210 is firmly connected. It would also be conceivable for the carrier 110 and the heat sink 210 to form a common, connected component. In other words, the carrier itself can have cooling fins or cooling pins, for example.

The vehicle headlight 101 comprises a light source 102 and a front lens system 103, the light source 102 being set up to emit light through the front lens system 103 and to bundle or shape it in the process.

Furthermore, the explanations of the arrangement and the method of the previous figures apply.

Reference symbol list:

1, 101

Vehicle headlights

2.102

Light source

3,103

Front optics

4.104

Circuit board

10.110

carrier

11

Contact surface

12.13

drilling

14.15

cavity

16, 17

Depth of the cavity

18, 19, 118

Thread in the bore of the carrier

20, 21, 120

Lanyard

22, 23

Lanyard axis

25th

Outside diameter of the connecting means

30, 31, 130

Spacer

35, 36

Height of the spacer

40.140

Bracket

41, 42

opening

45

Inner diameter of the opening

50

Microcapsule

51.151

adhesive

60, 61, 62, 63

Adjustment height

70.170

Crush rib

80, 81, 82

applied or generated force

210

Heatsink

Claims (16)

1. Vehicle headlamp (1, 101) comprising a light source (2, 102) and an auxiliary optics (3, 103), wherein the light source (2, 102) is configured to emit light through the auxiliary optics (3, 103) and the auxiliary optics (3, 103) is configured to focus or shape the light, and the light source (2, 102) is attached on a support (10, 110) provided in the vehicle headlamp (1, 101), the support being provided with a bore (12, 13) respectively for receiving at least one connecting means (20, 21, 120),
   at least one spacer element (30, 31, 130) is provided on the support (10, 110) on a respective bearing surface (11), the at least one spacer element (30, 31, 130) having a height (35, 36) normal to the bearing surface (11),
   a holding bracket (40, 140) on which at least one spacer element (30, 31, 130) is provided, the holding bracket (40, 140) being fixed to the auxiliary optics (3, 103) and having a respective opening (41, 42) provided for receiving the at least one connecting means (20, 21, 120),
   the at least one connecting means (20, 21, 120), extending along a respective axis (22, 23), is provided for connecting the retaining bracket (40, 140) to the support (10, 110) and for this purpose is inserted into the respective opening (41, 42) and into the respective bore (12, 13),
   characterized in that the retaining bracket (40, 140), when in a first position in which the at least one connecting means (20, 21, 120) is inserted into the opening (41, 42), but not fixed, can be moved within the opening (41, 42) in a plane normal to the axis (22, 23) relative to the at least one connecting means (20, 21, 120) in order to allow an alignment of the auxiliary optics (3, 103) fixed to the support bracket (40, 140) within the plane relative to the light source (2, 102) fixed to the support (10, 110), and
   the at least one spacer element (30, 31, 130) can be compressed by means of the at least one connecting means (20, 21, 120) through the retaining bracket (40, 140) and the support (10, 110), decreasing the height (35, 36) of the at least one spacer element (30, 31, 130) and attaining a fixed second position of the retaining bracket (40, 140).
2. The vehicle headlamp (1, 101) according to claim 1, characterized in that the modulus of elasticity of the at least one spacer element (30, 31, 130) is smaller than the modulus of elasticity of the retaining bracket (40, 140) and/or the support (10, 110),
   wherein preferably the modulus of elasticity of the at least one spacer element (30, 31, 130) is smaller than 80 kN/mm², preferably smaller than 30 kN/mm² and larger than 1 kN/mm², more preferably smaller than 4 kN/mm²,
   and preferably the yield strength of the at least one spacer element (30, 31, 130) is smaller than 100 kN/mm², preferably smaller than 80 kN/mm² and larger than 10 kN/mm², more preferably smaller than 70 kN/mm² and larger than 20 kN/mm².
3. The vehicle headlamp (1, 101) according to claim 1 or 2, characterized in that the vehicle headlamp comprises at least two spacer elements (30, 31, 130) and at least two connecting means (20, 21, 120), the at least two spacer elements (30, 31, 130) being provided so as to enable achieving an adjustment of the support bracket (40, 140) with respect to the support (10, 110), in which the at least two spacer elements (30, 31, 130) have a different heights (35, 36) in the adjusted position.
4. The vehicle headlamp (1, 101) according to any one of the preceding claims, characterized in that between the light source (2, 102) and the support (10, 110) a printed circuit board (4, 104) is provided, on which the light source (2, 102) is fixed.
5. The vehicle headlight (1, 101) according to one of the claims 1 to 3, characterized in that on the support (10, 110) a heat sink is provided or the support itself has cooling fins or cooling pins, and the at least one light source (2, 102) is attached to the support (10, 110), wherein preferably between the light source (2, 102) and the heat sink a printed circuit board (4, 104) is provided, on which the light source (2, 102) is fixed.
6. The vehicle headlamp (1, 101) according to claim 5, characterized in that the support (10, 110) has a through-hole through which the light source (2, 102) projects.
7. The vehicle headlamp (1, 101) according to any one of the preceding claims, characterized in that the support (10, 110) further comprises at least one cavity (14, 15), which each has a depth (16, 17), adapted to receive the at least one spacer element (30, 31, 130) and shaped substantially complementary to the outer contour of the at least one spacer element (30, 31, 130), wherein the height (35, 36) of the at least one spacer element (30, 31, 130) is greater than the depth (16, 17) of the at least one cavity (14, 15).
8. The vehicle headlamp (1, 101) according to any one of the preceding claims, characterized in that between the at least one spacer element (30, 31, 130) and the support (10, 110) and/or between the at least one spacer element (30, 31, 130) and the retaining bracket (40, 140) and/or between the at least one connecting means (20, 21, 120) and the support (10, 110) a layer is applied which contains an adhesive (51, 151) which preferably has a fluid form,
   wherein preferably the adhesive (51, 151) is embedded in a number of microcapsules (50) and is preferably carried by a fluid carrier material in which the number of microcapsules (50) is embedded,
   and preferably, by traction connection of the support (10, 110) to the holding bracket (40, 140) by means of the at least one connecting means (20, 21, 120), the number of microcapsules (50) burst at least partially and release the embedded adhesive (51, 151).
9. The vehicle headlamp (1, 101) according to any one of the preceding claims, characterized in that the at least one spacer element (30, 31, 130) has a spacer element opening in each case and preferably has a torus shape, and the at least one connecting means (20, 21, 120) is guided through the spacer element opening.
10. The vehicle headlamp (1, 101) according to any one of the preceding claims, characterized in that the at least one connecting means (20, 21, 120) is a screw, and preferably the bore (12, 13) of the support (10, 110) has a thread which is adapted to engage with the at least one connecting means (20, 21, 120).
11. The vehicle headlamp (1, 101) according to any one of the preceding claims, characterized in that the support (10, 110) comprises at least one crushing rib (70, 170) adapted to engage with the retaining bracket (40, 140) in the adjusted state.
12. Method for mounting and adjusting a light source (2, 102) and an auxiliary optics (3, 103) of a vehicle headlamp (1, 101) relative to one another, the light source (2, 102) being configured to emit light through the auxiliary optics (3, 103) and the auxiliary optics (3, 103) being configured to focus or shape the light, characterized in that the vehicle headlamp (1, 101) further comprises a support (10, 110) and a retaining bracket (40, 140), and the method steps are carried out of:

    - providing and fixing the light source (2, 102) in the region of a bearing surface (11) of the support (10, 110), where a bore (12, 13) is provided for receiving at least one connecting means (20, 21, 120) which extends longitudinally and has an axis (22, 23) along the direction of the longitudinal extension,

    - providing at least one spacer element (30, 31, 130) on the support (10, 110) and a retaining bracket (40, 140) on the spacer element (30, 31, 130), the retaining bracket (40, 140) being fixed to the auxiliary optics (3, 103) and having at least one opening (41, 42) which is provided to receive the at least one connecting means (20, 21, 120),

    - inserting the at least one connecting means (20, 21, 120) into the respective opening (41, 42) and into the respective bore (12, 13),

    - establishing an initial adjustment condition by aligning the attachment optics (3, 103) with the light source (2, 102) in an XY plane defined normal to the axis (22, 23),

    - fixing the initial adjustment state in the XY plane by connecting the support (10, 110) and the holding bracket (40, 140) by exerting a first force (80) using the at least one connecting means (20, 21, 120), achieving a first adjustment state with a first adjustment height (61),

    - establishing a third adjustment state in the XY plane and along the axis (22, 23) by exerting a third force (82) using the connecting means (20, 21, 120) between the support (10, 110) and the holding bracket (40, 140), achieving a third adjustment height (63).
13. The method according to claim 12, characterized in that before the step of inserting the at least one connecting means (20, 21, 120), an activatable adhesive (51, 151) is applied to the outer surface of the at least one spacer element (30, 31, 130) and/or the connecting means (20, 21, 120), and
    the following step is performed before the step of establishing the third adjustment state:

    - establishing a second adjustment state, wherein the adhesive (51, 151) is activated by exerting a second force (81) using the connecting means (20, 21) between the support (10, 110) and the holding bracket (40, 140), achieving a second adjustment height (62),

    and the following step is performed after the step of establishing the third adjustment state:

    - fixing the third adjustment state in the XY plane and in the direction of the axis (22, 23) at the third adjustment height (63) by curing the activated adhesive (51, 151).
14. The method according to claim 12 or 13, characterized in that, before providing the at least one spacer element (30, 31, 130), a layer is applied between the at least one spacer element (30, 31, 130) and the support (10, 110) and/or between the at least one spacer element (30, 31, 130) and the holding bracket (40, 140) and/or between the at least one connecting means (20, 21, 120) and the support (10, 110), the layer containing an activatable adhesive (51, 151), which preferably has a fluid form.
15. The method according to any one of claims 12 to 14, characterized in that the adhesive (51, 151) is embedded in a number of microcapsules (50) and is preferably carried by a fluid carrier material in which the number of microcapsules (50) is embedded, and the number of microcapsules (50) burst at least partially upon having a mechanical force applied to the microcapsules (50) and release the embedded adhesive (51, 151).
16. The method according to any one of claims 12 to 15, characterized in that the modulus of elasticity of the at least one spacer element (30, 31, 130) is smaller than the modulus of elasticity of the retaining bracket (40, 140) and/or the support (10, 110),
    wherein preferably the modulus of elasticity of the at least one spacer element (30, 31, 130) is less than 80 kN/mm², preferably less than 30 kN/mm², particularly preferably less than 4 kN/mm² and greater than 1 kN/mm,
    and preferably the yield strength of the at least one spacer element (30, 31, 130) is smaller than 100 kN/mm², preferably smaller than 80 kN/mm² and larger than 10 kN/mm², particularly preferably smaller than 70 kN/mm² and larger than 20 kN/mm².

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