Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F21—LIGHTING
  • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
  • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
  • F21S41/30—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by reflectors
  • F21S41/32—Optical layout thereof
  • F21S41/321—Optical layout thereof the reflector being a surface of revolution or a planar surface, e.g. truncated
• • G—PHYSICS
  • G02—OPTICS
  • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
  • G02B5/00—Optical elements other than lenses
  • G02B5/08—Mirrors
  • G02B5/0816—Multilayer mirrors, i.e. having two or more reflecting layers
  • G02B5/085—Multilayer mirrors, i.e. having two or more reflecting layers at least one of the reflecting layers comprising metal
  • G02B5/0875—Multilayer mirrors, i.e. having two or more reflecting layers at least one of the reflecting layers comprising metal the reflecting layers comprising two or more metallic layers
• • C—CHEMISTRY; METALLURGY
  • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
  • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
  • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
  • C25D5/10—Electroplating with more than one layer of the same or of different metals
  • C25D5/12—Electroplating with more than one layer of the same or of different metals at least one layer being of nickel or chromium
  • C25D5/14—Electroplating with more than one layer of the same or of different metals at least one layer being of nickel or chromium two or more layers being of nickel or chromium, e.g. duplex or triplex layers
• • C—CHEMISTRY; METALLURGY
  • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
  • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
  • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
  • C25D5/627—Electroplating characterised by the visual appearance of the layers, e.g. colour, brightness or mat appearance
• • C—CHEMISTRY; METALLURGY
  • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
  • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
  • C25D7/00—Electroplating characterised by the article coated
  • C25D7/08—Mirrors; Reflectors
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F21—LIGHTING
  • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
  • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
  • F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
  • F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
  • F21S41/141—Light emitting diodes [LED]
  • F21S41/147—Light emitting diodes [LED] the main emission direction of the LED being angled to the optical axis of the illuminating device
  • F21S41/148—Light emitting diodes [LED] the main emission direction of the LED being angled to the optical axis of the illuminating device the main emission direction of the LED being perpendicular to the optical axis
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F21—LIGHTING
  • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
  • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
  • F21S41/20—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
  • F21S41/25—Projection lenses
  • F21S41/255—Lenses with a front view of circular or truncated circular outline
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F21—LIGHTING
  • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
  • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
  • F21S41/30—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by reflectors
  • F21S41/32—Optical layout thereof
  • F21S41/322—Optical layout thereof the reflector using total internal reflection
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F21—LIGHTING
  • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
  • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
  • F21S41/30—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by reflectors
  • F21S41/37—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by reflectors characterised by their material, surface treatment or coatings
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F21—LIGHTING
  • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
  • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
  • F21S41/40—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by screens, non-reflecting members, light-shielding members or fixed shades
  • F21S41/43—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by screens, non-reflecting members, light-shielding members or fixed shades characterised by the shape thereof
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F21—LIGHTING
  • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
  • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
  • F21S41/60—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by a variable light distribution
  • F21S41/67—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by a variable light distribution by acting on reflectors
  • F21S41/675—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by a variable light distribution by acting on reflectors by moving reflectors
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F21—LIGHTING
  • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
  • F21V7/00—Reflectors for light sources
  • F21V7/22—Reflectors for light sources characterised by materials, surface treatments or coatings, e.g. dichroic reflectors
  • F21V7/28—Reflectors for light sources characterised by materials, surface treatments or coatings, e.g. dichroic reflectors characterised by coatings
• • G—PHYSICS
  • G02—OPTICS
  • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
  • G02B7/00—Mountings, adjusting means, or light-tight connections, for optical elements
  • G02B7/18—Mountings, adjusting means, or light-tight connections, for optical elements for prisms; for mirrors
  • G02B7/181—Mountings, adjusting means, or light-tight connections, for optical elements for prisms; for mirrors with means for compensating for changes in temperature or for controlling the temperature; thermal stabilisation

Definitions

• the field of the present invention is that of equipment for a motor vehicle and, more particularly, that of light projectors for these motor vehicles.
• Motor vehicle headlamps generally include an elliptical reflector in which a light source is arranged, a cut-off bar allowing various phases of occultation of the light beam and an optical lens diffusing the light beam created on the road.
• the cutoff bar is electrically actuated by an actuator to move, on command, between at least two angular positions in which it more or less obscures the light beam.
• This makes it possible to limit the range of the headlamp, for example to that of the low beams, called the code position, so as not to dazzle the drivers traveling in the opposite direction, or even to that of the high beams, called the high position, in which there is no concealment.
• This technology is commonly used with projectors comprising a high power light source, such as halogen or xenon lamp projectors, for which the loss of light power due to the interception of the flux by the bar is not really detrimental .
• LED diodes or LED for “Light-Emitting Diode”, in English
• the light power emitted by these devices remains for the moment still limited and it is necessary to use it to the best. It is therefore desirable to be able to do without the cut-off cover which absorbs, in the low beam position, substantially half of the light flux emitted.
• Document FR 3 028 002 proposes the use of a movable reflecting surface. By its mobility, this reflecting surface makes it possible to redirect the light beam to form, as desired, main beam or low beam, without having to make a cut and, therefore, without losing part of the power of the emitted light beam .
• this reflecting surface is exposed to external radiation, in particular solar radiation. It can therefore heat up by focusing the external radiation on said reflecting surface.
• This reflecting surface can be carried by a plastic support which can therefore be damaged by heating at the reflecting surface.
• the object of the present invention is to overcome these drawbacks by proposing a heat-resistant optical element.
• the invention relates to an optical element intended to modify a distribution of light beams for a motor vehicle headlamp.
• the optical element comprises a resin body having a functional surface covered with a reflective coating capable of reflecting the light beams, the reflective coating comprising:
• the heating produced at the functional surface can be dissipated by the copper layer.
• the optical element further comprises a nickel plating layer between the functional surface and the copper layer.
• the optical element includes a plating layer comprising a mixture of nickel and copper between the functional surface and the copper layer.
• the plating layer allows good adhesion of the reflective coating on the resin body.
• the nickel layer comprises:
• the functional surface has a semi-elliptical shape.
• the functional surface has a planar shape.
• the invention also relates to a headlight for a motor vehicle comprising at least one reflector and at least one light source capable of emitting at least one light beam, the reflector having the shape of a half-ellipsoid portion extending above of a plane of symmetry of the ellipsoid, the light source being positioned on an axis of symmetry of the ellipsoid.
• the projector further comprises an optical element as described above, the optical element being arranged to move to modify a distribution of the light beam emitted by the light source and reflected by the reflector.
• the light source is disposed substantially at a first focal point of the ellipsoid, the reflector being capable of reflecting the light beam (s) towards a second focal point of the ellipsoid, the functional surface of the optical element being arranged on the second home.
• the projector comprises a drive module configured to modify the position of the optical element between at least a first position of the optical element and a second position of the optical element, the first position of the optical element. making it possible to form a beam in the form of low beams at the exit from the headlight, the second position of the optical element making it possible to form a beam in the form of high beams at the exit from the headlight.
• the invention also relates to a method of manufacturing an optical element intended to modify a distribution of light beams as described above.
• the method comprises the following stages:
• the method further comprises a step of covering with a nickel plating preceding the first covering step.
• the method further comprises a step of covering with a plating comprising a mixture of nickel and copper preceding the first covering step.
• the second recovery step comprises:
• FIG. 1 represents a profile view of the headlight for a motor vehicle according to one embodiment
• FIG. 2 represents a perspective view of the optical element according to one embodiment
• FIG. 3 represents a cross section of the reflective coating on the body according to one embodiment
• FIG. 1 represents a headlight 13 for a motor vehicle.
• the projector includes at least one reflector 14 and at least one light source 15 capable of emitting at least one light beam 17.
• light beam will be used in the singular. However, it will be understood that this term can also mean “light beams” in the plural.
• the reflector 14 has a shape of a half-ellipsoid portion extending above a plane of symmetry 16 of the ellipsoid.
• the light source 15 is positioned on an axis of symmetry of the ellipsoid.
• the light source may include at least one LED diode which emits on a solid angle of 2p steradians so that the entire light beam emitted by the light source is reflected by the reflector.
• the projector 13 also comprises an optical element 1 arranged to be movable for modifying a distribution of the light beam 18 emitted by the light source 15 and reflected by the reflector 14.
• the light source 15 is disposed substantially at a first focus of the ellipsoid.
• the reflector 14 is then able to reflect the light beam 17 towards a second focal point of the ellipsoid.
• the projector may also include a lens 18 disposed on the path of the light beam 17 after said light beam 17 has been reflected on the reflector 14 then cut and / or reflected by the optical element 1.
• the lens 18 is convergent .
• the projector 13 comprises a drive module 16 configured to modify the position of the optical element 1 between at least a first position of the optical element 1 and a second position of the optical element 1.
• the first position of optical element 1 forms a beam in the form of low beams at the exit from the headlamp 13.
• the second position of the optical element 1 makes it possible to form a beam in the form of main beams at the exit from the headlamp 13.
• the optical element 1 intended to modify a distribution of light beams is shown in FIG. 2.
• the optical element 1 comprises a resin body 2 having a functional surface 3 covered with a reflective coating 4 capable of reflecting the light beam.
• the resin may be polyphthalamide (PPA) reinforced with glass fibers (PPA GF25-40%).
• PPA polyphthalamide
• PPA GF25-40% polyphthalamide reinforced with glass fibers
• the resin can be reinforced PPA (PPA MR 30%).
• PPA MR 30% is preferred for its dimensional stability. Indeed, successive coatings tend to amplify any appearance defects.
• the functional surface 3 of the optical element 1 is disposed substantially at the second focal point of the ellipsoid.
• the functional surface 3 can have a semi-elliptical shape or a planar shape.
• the semi-elliptical shape of the functional surface 3 can correspond to a concave semi-elliptical shape located outside the focal plane of the ellipsoid, between the lens 18 and the focal plane, allowing a reflection of the light source 15 to achieve distribution. additional light dimmed, above the code light to increase the visibility of vertical traffic signs.
• the reflective coating 4 comprises (FIG. 3): a copper layer 5 covering, at least in part, the functional surface 3,
• the copper layer 5 corresponds to a heat conducting layer. Said copper layer 5 dissipates the heat produced by heating at the functional surface 3 by the external radiation 19. It also has good resistance to high temperatures and temperature changes.
• the copper has good adhesion with the resin body material 2 and the nickel layer 6.
• the copper layer 5 also provides good elasticity to the reflective coating 4.
• the projector 13 comprises a converging lens 18
• heating of the functional surface 3 caused by the convergence of the external radiation 19 on said functional surface 3 can be dissipated by the copper layer 5.
• heating is not localized to the place where the external radiation 19 converges. This avoids the destruction of the resin body 2.
• the copper layer 5 has a thickness of between 15 ⁇ m and 25 ⁇ m, preferably 20 ⁇ m.
• the nickel layer 6 makes it possible to resist corrosion of the reflective coating 4. It also has good resistance to climatic cycles.
• the chromium layer 7 makes it possible to provide hardness to the reflective coating 4 as well as a shine.
• the chromium layer has a thickness of between 0.1 ⁇ m and 1 ⁇ m, preferably 0.25 ⁇ m.
• the reflective coating further comprises a plating layer 8 between the functional surface 3 and the copper layer 5.
• the plating layer 8 may be made of nickel or may comprise a mixture of nickel and copper.
• the plating layer comprises from 50% to 70% of copper and from 50% to 30% of nickel. Preferably, the plating layer comprises about 60% copper and 40% nickel.
• the plating layer 8 improves the adhesion of the copper layer 5 on the resin body 2.
• the plating layer has a thickness of between 0.5 ⁇ m and 1.5 ⁇ m, preferably 1 ⁇ m.
• the nickel layer 6 comprises:
• the semi-gloss nickel sublayer 9 provides good adhesion of the copper layer 5 with the nickel layer 6. It also provides good corrosion resistance of the reflective coating 4.
• the semi-shiny nickel sublayer 9 has a low sulfur content of between 0.002% and 0.005% by mass.
• the semi-gloss nickel sublayer 9 has a thickness of between 10 ⁇ m and 20 ⁇ m, preferably 15 ⁇ m.
• the high-sulfur nickel undercoat 10 allows good adhesion of the semi-bright nickel undercoat 9 and the bright nickel undercoat 11.
• the nickel sub-layer with a high sulfur content 10 has a sulfur content of between 0.1% and 0.25% by mass.
• high content for "high sulfur nickel” means that the nickel comprises a sulfur content ranging from 0.1% to 0.25% by mass.
• the nickel sub-layer with a high sulfur content 10 has a thickness of between 1.5 ⁇ m and 2.5 ⁇ m.
• the shiny nickel sublayer 11 provides good gloss of the reflective coating 4 and an improvement in the hardness of the reflective coating 4.
• the bright nickel sublayer 11 has a thickness of between 5 ⁇ m and 15 ⁇ m, preferably 10 ⁇ m.
• the matt nickel underlayer 12 provides the reflective coating 4 with a shiny surface identical to a mirror.
• the sub-layer of matt nickel 12 has a thickness of between 5 ⁇ m and 15 ⁇ m, preferably 10 ⁇ m.
• specular reflection can be linked by a relationship between a diffuse reflection and a specular reflection (reflectivity).
• a reflection can be said to be diffuse when an incident ray is reflected in a large number of directions, while a reflection is said to be specular when an incident ray is reflected in one direction.
• the term "mat” can mean that diffuse reflection is more important than specular reflection.
• the light energy reflected by diffusion is therefore greater than the light energy reflected in a specular manner.
• specular can mean that specular reflection is more important than diffuse reflection.
• the light energy reflected in a specular manner is therefore more important than the light energy reflected by diffusion.
• specular reflection is substantially as high or substantially lower than the diffuse reflection.
• the light energy reflected in a specular manner is therefore substantially equal to or substantially less than the light energy reflected by diffusion.
• a glossy surface has a reflectivity (specular reflection) of between 50% and 100%, a semi-glossy surface of between 20% and 50% and a matt surface of less than 20%.
• the optical element 1 can be manufactured by a manufacturing process which comprises the following steps:
• the step of forming the resin body 2 can be carried out by molding the resin or by 3D printing.
• the first recovery step can be carried out with chemical copper plating.
• the second recovery step can be carried out by electroplating.
• the third recovery step can be carried out by electroplating.
• the method comprises a step of covering with a nickel plating 8 or a mixture of nickel and copper preceding the first covering step.
• the step of covering with a plating 8 can be carried out by electroplating.
• the second recovery step comprises:
• Each of the substeps can be implemented by electroplating.
• the first covering substep may include depositing a layer of matt nickel and polishing the layer of matt nickel.
• the third recovery sub-step may include the deposition of a layer of matt nickel and the dipping of the layer of matt nickel in a bath containing brightening additives.

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• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Physics & Mathematics (AREA)
• Metallurgy (AREA)
• Electrochemistry (AREA)
• Materials Engineering (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Organic Chemistry (AREA)
• General Engineering & Computer Science (AREA)
• Optics & Photonics (AREA)
• General Physics & Mathematics (AREA)
• Microelectronics & Electronic Packaging (AREA)
• Non-Portable Lighting Devices Or Systems Thereof (AREA)
• Optical Elements Other Than Lenses (AREA)

Applications Claiming Priority (2)

Publications (1)

Family

ID=65031379

Family Applications (1)

Country Status (7)

Family Cites Families (14)

• 2018
  • 2018-07-06 FR FR1856230A patent/FR3083624B1/fr active Active
• 2019
  • 2019-07-05 JP JP2021522153A patent/JP7397866B2/ja active Active
  • 2019-07-05 WO PCT/FR2019/051668 patent/WO2020008154A1/fr unknown
  • 2019-07-05 CN CN201980045112.XA patent/CN112424527A/zh active Pending
  • 2019-07-05 KR KR1020217003460A patent/KR20210027464A/ko not_active Application Discontinuation
  • 2019-07-05 US US17/258,044 patent/US11487052B2/en active Active
  • 2019-07-05 EP EP19742884.0A patent/EP3814679A1/fr active Pending

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