EP3899355A1

EP3899355A1 - Motor vehicle headlamp and method for orienting at least one light source of a motor vehicle headlamp

Info

Publication number: EP3899355A1
Application number: EP19832031.9A
Authority: EP
Inventors: Stefan ESTERLE
Original assignee: ZKW Group GmbH
Current assignee: ZKW Group GmbH
Priority date: 2018-12-18
Filing date: 2019-12-16
Publication date: 2021-10-27
Also published as: EP3671013A1; WO2020127005A1

Abstract

The invention relates to a motor vehicle headlamp (1) having at least one light source (10), arranged on a circuit board (30), and at least one optical system (20). The at least one light source (10) has a light-emitting area (11) and is designed to emit generated light from the light-emitting area (11) towards (S₁) the optical system (20). The circuit board (30) comprises: a main circuit board (31); at least one sub-circuit board (33), which is equipped with the at least one light source (10); and at least one flexible circuit board portion (32), which connects the main circuit board (31) with the sub-circuit board (33). The sub-circuit board (33) can be connected, at least in part, to at least one carrier body (40) and the carrier body (40) is designed, when in a position in which the carrier body is connected to the sub-circuit board (33), to fix the sub-circuit board (33) in a position which is pivoted by an angle of inclination (α) relative to the main circuit board (31). The generated light is emitted from the at least one light source (10) at this angle of inclination (α). The invention further relates to a method for orienting at least one light source (10) of a motor vehicle headlamp (1) towards an optical system (20).

Description

MOTOR VEHICLE HEADLIGHTS AND METHOD FOR ALIGNING AT LEAST

A LIGHT SOURCE OF A MOTOR VEHICLE HEADLAMP

The invention relates to a motor vehicle headlight with at least one light source which is arranged on a printed circuit board, and with at least one optical system, the at least one light source having a light-emitting surface and being set up to emit generated light from the light-emitting surface in the direction of the optical system , as well as the optical system is set up to emit light in a desired direction as on a track. A method for aligning at least one light source of a motor vehicle headlight in the direction of an optical system is also specified.

The use of motor vehicle headlights in which one or more light sources are designed, for example, as LEDs, the light sources being attached to or on printed circuit boards, has long been known. The circuit boards not only fulfill the function of the direct support for such light sources, but also serve for the power supply and electronic control of those arranged thereon

Light sources. In order to be able to install such light sources such as LEDs in headlights such as for example headlights or rear lights of a motor vehicle, printed circuit boards are nowadays used which are already glued to a carrier plate, for example made of aluminum, before these so-called “printed circuit boards on aluminum” are subsequently used with one or more LEDs By gluing the circuit board to a flat contact surface of a heat transfer body, for example made of aluminum or copper, the heat dissipation of the light sources during operation of the motor vehicle headlights is correspondingly improved by the use of reinforced reinforcements already glued flat to a flat or planar support plate

Printed circuit boards which are subsequently fitted with the LEDs, the stability of such “printed circuit boards on aluminum” as supports or supports for the light sources fitted thereon are significantly increased and the desired vibrations of the light sources during operation of the vehicle are correspondingly reduced.

Furthermore, flexible printed circuit boards are already used for motor vehicle headlights, which are glued to such an aluminum carrier plate and which are subsequently fitted with LEDs. Such flexible printed circuit boards offer the advantage that two or more rigid printed circuit board areas, each of which is glued to a carrier board and equipped with LEDs, can be pivoted in their position relative to one another by means of flexible printed circuit board areas lying between them. This makes it possible to meet new requirements regarding Lorm and design in a more contemporary way

Motor vehicle headlights meet better because of the use of such flexible Printed circuit boards the space required for their installation inside a headlight housing can be reduced. However, here too, those light sources which are jointly fastened to the same rigid circuit board section can only be aligned together in a coplanar manner, so that these light sources usually radiate perpendicularly from the plane of the rigid circuit board section.

However, a disadvantage of those known from the prior art

Motor vehicle headlights at least that when using, for example, LED modules that consist of several light sources, these multiple light sources must be perfectly coordinated with respect to their installation position, in order to prevent, among other things, the formation of unwanted scattered light. Such stray light formation can - depending on the respective legal regulation - lead to problems with the

Homologation of motor vehicle headlights due to the norms and limits to be met. However, an individual setting and specific coordination of the individual light sources with regard to their inclination and positioning in relation to one another or in relation to a circuit board level is neither intended nor would it be due to the “circuit boards on aluminum” which are currently used and have previously been glued to carrier boards the space required and high costs for use in the motor vehicle sector possible.

One of the objects of the present invention is to provide a

Motor vehicle headlights of the type described to overcome the disadvantages known from the prior art. In addition, a generic

Motor vehicle headlights are specified in which the design freedom for the design of modern motor vehicle headlights, which are usually equipped with a large number of individual light sources, each arranged on or on printed circuit boards, is further increased. Another object of the invention is to provide a generic

Motor vehicle headlights specify the complexity of the assembly and

Adjustment of non-coplanar optical components is significantly reduced compared to currently known headlights.

In the context of the present invention, a particularly flexible assembly or alignment method is also to be specified, which allows individual light sources arranged on or on printed circuit boards to be made as inexpensively as possible, each in an individual, coordinated positioning relative to one another

To mount the vehicle headlight housing.

These objects are achieved with a motor vehicle headlight of the type mentioned at the outset, in which the printed circuit board is a base printed circuit board, at least one sub-printed circuit board equipped with the at least one light source and at least one flexible one

PCB section, which flexible circuit board section the basic PCB movably connects to the sub-circuit board, the sub-circuit board being connectable, at least in sections, to at least one carrier body and the at least one carrier body being set up in a position connected to the sub-circuit board, the at least one sub-circuit board in one under a

Fix angle of inclination relative to the base circuit board pivoted position, wherein the generated light is emitted at this angle of inclination from the at least one light source.

In the context of the invention, the term optical system is understood to mean the lenses, mirrors, prisms, light guides, optical lenses, diaphragms and / or reflectors which produce an optical image, together with the brackets and fastening devices required for their assembly. For example, a motor vehicle headlamp according to the invention can comprise a first optical system which has one or more optical lenses, each of which can be of the same or a different design. Likewise, a motor vehicle headlight according to the invention can, for example, comprise a second, third and / or further optical system which differs from the aforementioned first optical system and which, for example, has one or more reflectors and / or light guides of the same or different construction. Depending on the design variant and application for which the motor vehicle headlight is intended, a common optical system or several identical optical systems or several different optical systems can be used in one

Motor vehicle headlights according to the invention may be provided.

The at least one light source of the motor vehicle headlight has a light-emitting surface in a manner known per se and is set up to emit the generated light from the light-emitting surface in the direction of the at least one optical system, the at least one optical system which, for example, has one or more optical systems Lenses and / or reflectors can be set up to emit light in the operation of the motor vehicle headlight in a specific, desired direction as on a road.

For the preferred application, according to which LED light sources are used as light sources, the at least one sub-printed circuit board being equipped with one or more LEDs, the light emission direction of such an LED light source is to be understood in the context of the present application document, its main light beam direction. As is known to the person skilled in the art, LEDs are diffuse Lambertian emitters

Beam characteristics can vary depending on the application and the type of LEDs. In addition to narrow and wide lobes (right down to the Lambert spotlight), LED light sources can also have more or less deformed radiation characteristics. For example, so-called Batwing LEDs, two of which are mentioned as examples Have light intensity maxima and whose light intensity distribution is rather heart-shaped, as well as so-called side-emitter LEDs with a light intensity maximum that is approximately normal to the beam axis. To the possible different

Taking the radiation characteristics of LED light sources into account, their main light beam direction is used as the reference variable for the light beam direction.

The individual angle of inclination of the sub-circuit board pivoted relative to the base circuit board is selected such that the main light beam direction of the generated light is oriented in the desired direction towards the at least one optical system at precisely this angle of inclination.

This motor vehicle headlight according to the invention advantageously has a

Printed circuit board for use, which has a basic printed circuit board, at least one sub-printed circuit board equipped with the at least one light source and at least one flexible one

Has circuit board section, wherein the flexible circuit board section movably connects the base circuit board with the sub-circuit board. The flexible circuit board section expediently has fewer layers or layers in comparison to the base circuit board and / or the at least one sub-circuit board.

Such flexible printed circuit boards are used in many areas of electronics today. The circuit board is usually bent, twisted or folded into a housing. The use of flexible printed circuit boards primarily replaces cables and connectors or creates connections and geometries that cannot be achieved with a rigid printed circuit board.

Furthermore, semi-flexible circuit boards are known which differ from the flexible circuit boards in the materials used, limited bending radii and bending cycles. Instead of a polyimide material, a standard thin laminate FR4 material is usually used to offer an inexpensive alternative for certain applications. The term "FR4" is familiar to the person skilled in the art and denotes a class of flame-retardant and flame-retardant composite materials consisting of epoxy resin and glass fiber fabric. Such semi-flexible printed circuit boards have a more stable structure than flexible printed circuit boards, which makes handling during assembly easier.

So-called “rigid-flex” printed circuit boards are also known, in which fixed, rigid areas of the printed circuit board and flexible “flex” areas are connected to one another with a reduced number of layers compared to the rigid areas. For example, material combinations of polyimide and FR4 laminate or combinations of FR4 and thin laminate are used to manufacture such rigid-flex circuit boards. By using Rigid-Flex circuit boards, the rigid circuit boards without the use of cables or Connecting connections together, an improved signal transmission between the circuit boards can be achieved.

Within the scope of the invention, it can furthermore be advantageous, for reasons of cost, if a multi-layer standard circuit board is provided for equipping with one or more light sources, in which one or more sub-circuit board areas on the standard circuit board are partially free - comparable to panel separation joints one

Manufacturing benefits for separating circuit boards. In general, a benefit layout is selected depending on the circuit board design or on the contour and structure of the circuit boards, on the specified accuracy for the separation, the permissible mechanical stress during separation, the cycle time, as well as the quality specifications and costs.

For this purpose, the clearances between a sub-circuit board area and the base circuit board are expediently arranged in the processing of a multi-layer standard circuit board in such a way that the sub-circuit board area has, for example, a rectangular or square floor plan which is equipped with one or more light sources. In the case of an internal sub-printed circuit board, the exemptions are preferably arranged on three of the four of their side edges opposite the basic printed circuit board surrounding the sub-printed circuit board. So that a flexible circuit board section is formed as a movable connection between the base circuit board and the sub-circuit board, some of the circuit board layers are expediently removed in this area by means of a deep milling cutter. The flexible circuit board section therefore has fewer layers or layers in comparison to the base circuit board and / or the at least one sub-circuit board.

At least one securing web, which is in the region of the

Exemption between the base circuit board and the at least one sub-circuit board, which is equipped with at least one light source, and these two

PCB areas still connected to each other during assembly, for securing and stabilizing the at least one sub-circuit board to be assembled in one

Departure days at the level of the printed circuit board. The at least one is expedient

The safety bar is only cut after the circuit board has been fitted with the appropriate optical components, such as the light sources, and before the main circuit board has been installed. The one or more securing bars ensure during the manufacture of the printed circuit board or during the assembly with optical and / or

electronic parts and components for the necessary stability of the sub-circuit board sections. For example, it can be equipped with optical components such as light sources using SMT technology (Surface-Mounting Technology). As soon as the at least one securing web between the base circuit board and the at least one is cut through a sub-circuit board, the correspondingly exempted sub-circuit board is movably connected to the base circuit board by means of the flexible circuit board section.

In this way, multilayer standard printed circuit boards can be used at particularly low cost, the production of which is significantly cheaper than film conductors or so-called flexprints with several individual prints or else as the flatly bonded "printed circuit boards on aluminum" mentioned at the beginning.

In contrast to headlights with the "printed circuit boards on aluminum" mentioned at the beginning, that is to say flexible printed circuit boards which are already glued flat to a support plate made of aluminum or copper and which are only subsequently fitted with LEDs

Motor vehicle headlights according to the invention have the essential advantage that here only one or more sub-circuit boards equipped with light sources with at least one

Carrier bodies are connected and the at least one carrier body is set up to fix the at least one sub-circuit board in a position connected to the sub-circuit board in a position pivoted at an angle of inclination relative to the main circuit board, the main light beam direction of the generated light below this

Inclination angle - based on the level of the base circuit board - from which at least one light source is emitted.

Thus, only that circuit board section of a sub-circuit board equipped with light sources is advantageously made by means of one or more carrier bodies in a defined,

pivoted position fixed relative to the base circuit board, in order to be able to align and adjust the light beams emitted by the at least one light source according to a light function as precisely as possible in this fixed position. This type of individual storage and fixation of only those sub-circuit boards that are actually equipped with light sources offers much greater flexibility with regard to the individual adjustability and alignment of the corresponding light sources. Furthermore, this offers an opportunity to increase the design freedom and the design due to the reduced circuit board dimensions without continuous aluminum carrier plates

To reduce the dimensions of the housing of a motor vehicle headlight according to the invention by a particularly compact design.

The at least one carrier body can advantageously be made in one piece or in one piece and can have corresponding contact surfaces, projections, fastening devices and / or holding devices in order to fix one or more sub-printed circuit boards in positions pivoted relative to the base printed circuit board.

It can also be expedient in the context if the carrier body is made of several parts and if, for example, each part of the multi-part carrier body can be connected to a sub-circuit board or serves to support and fix a sub-circuit board. Furthermore, it is conceivable within the scope of the invention that several mutually independent carrier bodies are provided, each of which can be connected to one or more sub-printed circuit boards and are used for fixing them in a position pivoted at an individual angle of inclination with respect to the basic printed circuit board.

For example, the carrier bodies can be shaped like ramps or wedges at least in sections and can be arranged on the back of the front sides of the sub-printed circuit boards equipped with the light sources.

In a preferred embodiment of the invention, in the case of a motor vehicle headlight, the at least one light source can be from a first position in which the sub-circuit board equipped with the at least one light source and the at least one carrier body in

disconnected position are separated from each other, along a spatial

Movement path, in particular by tilting, pivoting and / or rotating into a second position, in which the sub-circuit board equipped with the light source and the at least one carrier body are fixed to one another in a connected position, can be transferred. Advantageously, the one or more sub-circuit boards equipped with light sources can be tilted, pivoted, rotated, for example, from an initial position in the plane of the base circuit board into the respective fixed installation positions in which the sub-circuit boards are attached to one or more carrier bodies and / or be moved. Individual sub-printed circuit boards equipped with light sources can thus advantageously be adapted particularly flexibly in their individual installation positions to the required lighting tasks of the motor vehicle headlight.

It can be particularly expedient if in an inventive

Motor vehicle headlights in the fixed position, pivoted at an angle of inclination relative to the base circuit board, of the sub-circuit board equipped with the at least one light source, in which the sub-circuit board is connected to the at least one carrier body and emitted by the at least one light source

Main light beam direction is aligned in the direction of the at least one optical system.

The light-emitting surfaces of the light sources therefore do not necessarily have to have the same main emission direction, for example essentially normal to the front of the base circuit board, as is the case with conventional circuit boards or also with the aforementioned “circuit boards on aluminum”. Due to the flexible assembly and Due to the individual, coordinated positioning of the sub-circuit boards relative to one another in a vehicle headlight housing, the emitted light can be aligned particularly efficiently with one or more optical systems such as, for example, optical lenses or reflectors, which advantageously increases the light yield. In another advantageous embodiment, in a motor vehicle headlight according to the invention with a sub-printed circuit board equipped with a plurality of light sources, which is pivoted in a fixed position ver at an angle of inclination relative to the base printed circuit board, is connected to the at least one support body, which is one of the plurality Light sources emitted light beams or their main light beam directions are aligned together in the direction of the at least one optical system.

In a further development of the invention, in a motor vehicle headlight according to the invention, in which the printed circuit board has a plurality of sub-printed circuit boards each equipped with at least one light source, which are movably connected to the base printed circuit board with flexible printed circuit board sections, the plurality of sub-printed circuit boards equipped with light sources each be connected to the at least one carrier body in fixed positions pivoted at individual angles of inclination relative to the base circuit board.

The plurality of assembled sub-printed circuit boards can, for example, be arranged so as to be free within the basic printed circuit board by means of corresponding openings. Likewise, it is provided in the context of the invention that sub-printed circuit boards outside the basic printed circuit board are connected to the basic printed circuit board with corresponding flexible printed circuit board sections. For this purpose, the sub-printed circuit boards can be attached to one another in series with one another, parallel to one another and / or in a matrix arrangement to one another or in relation to the base printed circuit board.

In a further advantageous embodiment of the invention, one

Motor vehicle headlights have the circuit board a plurality of sub-circuit boards each equipped with at least one light source, which are arranged in a matrix-like manner with respect to one another, the plurality of sub-circuit boards equipped with light sources each being connected to the at least one support body in fixed positions pivoted at individual angles of inclination relative to the base circuit board are.

Such a matrix-type arrangement offers the advantage, in particular when matrix LED modules are used, which consist of a plurality of light sources arranged in rows and / or in columns, that these light sources are inclined with respect to their inclination due to the flexible mounting of the light sources on sub-printed circuit boards and position can be coordinated as best as possible. It is also within the scope of the invention

provided that on the individual sub-circuit boards, which are adjustable in their inclination and / or position relative to the base circuit board, also several light sources

can be arranged. For example, in a matrix arrangement, individual columns or rows of LED light sources can each be arranged on a sub-circuit board. In a motor vehicle headlight according to the invention, the light beams emitted by the light sources arranged on the plurality of sub-circuit boards or their main light beam directions are expediently oriented in the direction of the at least one optical system.

In a development of the invention, a motor vehicle headlight can comprise at least two optical systems, at least one first sub-printed circuit board equipped with light sources being connected to the at least one support body in a fixed position which is pivoted at a first inclination angle relative to the basic printed circuit board and which main light beam direction emitted by the at least one light source is oriented in the direction of a first optical system, and at least one second sub-circuit board equipped with light sources is connected to the at least one carrier body in a fixed position which is pivoted relative to the base circuit board at a second inclination angle and that emitted by the at least one light source

Main light beam direction is aligned in the direction of a second optical system.

A wide variety of design variants are conceivable for this purpose: for example, each optical system can be independent of one another

Carrier bodies are used, which are each individually adjustable and with the help of which the sub-printed circuit boards can be aligned in their position attached to the respective carrier body to the respective assigned optical system. In this way, for example, different optical systems can be used for different ones

Lighting functions such as low beam, parking light, flashing light, cornering light or high beam are provided with individually adjusted, optimally aligned light beams that are emitted by the respectively assigned light sources.

Likewise, a carrier body can be used within the scope of the invention

For example, is made in several parts and in which a first carrier body part or section for fastening sub-circuit boards, the light sources of which are aligned with the first optical system, and a second carrier body part or section for fastening sub-circuit boards, the light sources of which second optical system are aligned, is provided.

It can be particularly advantageous if a device according to the invention is used

Motor vehicle headlamp which has at least one support body has at least one support surface, on which at least one sub-printed circuit board equipped with the light source is fastened in its position connected to the support body.

In this execution _V ersion the carrier has a body with corresponding bearing surfaces has the advantage that the assembled circuit boards can be sub-surface attached to these supporting surfaces. As a result, a largely vibration-free bracket with the Sub-circuit boards equipped with light sources are guaranteed and this embodiment variant is also particularly robust and stable, since the sub-circuit boards are particularly well protected from mechanical loads by the support surfaces of the at least one carrier body, which are fastened to their rear sides facing away from the light sources. The

For this purpose, contact surfaces are expediently planar and are preferred

Execution at least so large that the entire

Contact surface of the respective sub-printed circuit boards.

In a further advantageous embodiment of the invention, one

Motor vehicle headlights, the at least one carrier body can be formed as a heat sink and the at least one sub-circuit board equipped with the light source can be attached to the at least one support surface of the carrier body in a heat-conducting manner, preferably with a heat-conducting adhesive layer.

In this embodiment, the respective carrier body advantageously acts as a heat sink and is expediently made from a heat-conducting metal, preferably from aluminum and / or copper or corresponding alloys. Thermally conductive adhesives are widely used for the heat dissipation of power electronics. In this way, the heat-conducting adhesives reduce the heat load when gluing heat sinks and thus ensure the performance of electronic components. The heat-conducting adhesives are synthetic resins that are enriched with appropriate metallic or inorganic fillers. The best thermal conductivity values can be achieved with metallic fillers such as silver or graphite. This will make the

Adhesive, however, is also electrically conductive, which is not desirable in many applications. In order to achieve pure thermal conductivity with simultaneous electrical insulation, adhesives must be used that are mixed with ceramic or mineral fillers.

Compared to thermal pastes, thermally conductive adhesives have the advantage that they not only dissipate the high thermal energy, but also serve to fix and fasten components.

A motor vehicle headlight according to the invention can be used and tuned particularly flexibly, in which the carrier body has at least one holding device with which the at least one sub-circuit board equipped with the light source can be fixed to the carrier body in its position pivoted at an angle of inclination relative to the base circuit board, wherein The inclination angle of the sub-circuit board attached to it can preferably be adjusted with the holding device.

The sub-printed circuit boards can also be mounted on the at least one carrier body on corresponding holding devices which are arranged on the carrier body. For example, wedge-shaped or obliquely arranged screw mounts or clamp mounts can be used to fasten the sub-circuit boards in fixed positions pivoted at angles of inclination relative to the base circuit board. Likewise, within the scope of the invention, various designs of optics holders known per se, which are arranged on the at least one support body, can serve as press holders for fastening the sub-printed circuit boards. Such holding devices are preferably designed to be movable and allow fine adjustment of the angle of inclination of the sub-printed circuit boards already attached to them in relation to the plane of the base printed circuit board or in relation to a selected assembly plane.

In a motor vehicle headlight according to the invention, the at least one light source arranged on the sub-circuit board can expediently be designed as an SMD LED module, as a COB LED module or as a MCOB LED module. A so-called SMD LED module (surface-mount device light-emitting diode module) is an embodiment variant of an LED module in which LED chips are attached to printed circuit boards (printed circuit boards, PCB) by means of SMT technology (surface-mount technology). An SMD LED module can optionally be designed so that it functions independently and is ready for use, or that it can be integrated, for example plugged in, in a functional unit with a corresponding power supply and corresponding control lines for controlling the individual electronic components. Other types of LED lighting devices include the newer and particularly powerful COB (chip on board) and MCOB (multi-COB) technology.

With this embodiment according to the invention can thus be compared to

Vehicle headlights used “circuit boards that are complex to produce

Aluminum "at least the following advantages:

More flexible coordination with regard to the inclination and positioning of individual light sources that are arranged on a circuit board;

Lower manufacturing costs due to a reduced number of printed circuit boards;

Lower manufacturing costs of the printed circuit boards, since in the context of the invention preferably multilayer standard printed circuit boards which are not laminated on aluminum carrier boards can be used;

Support of the printed circuit boards by one or more carrier bodies only required in the area of the tilted or inclined sub-printed circuit boards;

Use of standard LEDs approved for motor vehicles also for

Applications with tilted or inclined main emission directions possible. The above-mentioned objects are also achieved with a method according to the invention for aligning at least one light source of a motor vehicle headlight in the direction of an optical system, the at least one light source having at least one light-emitting surface and being set up to emit generated light from the light-emitting surface. Such a process comprises the following steps:

Providing a circuit board with a base circuit board, with at least one sub-circuit board which is equipped with at least one light source, and with at least one flexible circuit board section which movably connects the base circuit board to the at least one sub-circuit board;

Providing at least one carrier body which is set up to fix the at least one sub-circuit board in a position connected to the sub-circuit board in a position pivoted at an angle of inclination relative to the base circuit board;

Transferring the at least one sub-printed circuit board equipped with a light source along a spatial movement path, in particular by tilting,

Pivoting and / or rotating into a position pivoted at an angle of inclination relative to the base circuit board, in which the at least one sub-circuit board bears at least in sections on the at least one carrier body and / or on at least one holding device of the carrier body;

Fixing the at least one sub-circuit board equipped with a light source to the at least one carrier body in a position pivoted at an angle of inclination relative to the base circuit board, the position of the at least one

Light source generated light is emitted at this angle of inclination from the at least one light source in the direction of the optical system;

Assemble the circuit board together with the at least one carrier body, which is attached to the at least one sub-circuit board, in the installed position within the

Motor vehicle headlights.

With regard to the advantages of this method according to the invention, reference is made to the advantages and advantageous effects already discussed above with reference to the motor vehicle headlight according to the invention, which analogously also apply to the alignment method according to the invention.

In a further advantageous embodiment of the method according to the invention, the circuit board can have a plurality of sub-circuit boards each equipped with at least one light source, which are movably connected to the base circuit board with flexible circuit board sections, the plurality of sub-circuit boards each equipped with light sources are connected to the at least one carrier body in fixed positions pivoted at individual angles of inclination relative to the base circuit board, and the light emitted by the light sources arranged on the plurality of sub-circuit boards

Main light beam directions are aligned in the direction of the at least one optical system.

If necessary, the individual assembled sub-circuit boards can be fixed individually and independently of one another in installation positions that are also inclined

Allow the main emission directions of the emitted light beams in relation to the plane of the base circuit board. The alignment of the emitted light beams in the direction of one or more optical systems can thus be set particularly flexibly.

In a development of the method according to the invention, the

Motor vehicle headlights comprise at least two optical systems, at least one first sub-printed circuit board equipped with a light source being connected to the at least one carrier body in a fixed position pivoted at a first inclination angle relative to the base printed circuit board, the one of which is connected to this sub-printed circuit board arranged light source, emitted light beams are aligned in the direction of the first optical system in accordance with their main light beam direction, and at least one second sub-printed circuit board equipped with a light source in one under a second

Tilt angle pivoted relative to the base circuit board, fixed position is connected to the at least one carrier body, the light beams emitted by the light source arranged on this sub-circuit board being aligned in the direction of the second optical system according to their main light beam direction.

In this way, for example, different optical systems can be used for

different lighting functions such as low beam, parking light, flashing light,

Cornering lights or high beams are provided, with individually adjusted, optimally aligned light beams, which are emitted by the respectively assigned light sources.

It can be particularly expedient if, in a method according to the invention, the at least carrier body is designed as a heat sink and the at least one sub-circuit board equipped with the light source is attached in a pivoted, fixed position, preferably with a heat-conducting adhesive layer, to at least one support surface of the carrier body becomes.

Here, too, reference is made to the advantages of using a heat sink as the support body, which have already been discussed above. The heat sink is expediently made of a heat-conducting metal, preferably of aluminum and / or copper or corresponding alloys. Due to the preferential use of a thermally conductive adhesive for flat Attachment of the at least one sub-circuit board to the heat sink, the waste heat of the light sources can be dissipated particularly efficiently through the sub-circuit board into the heat sink attached or glued to the rear of the sub-circuit board during operation of the motor vehicle headlight. Appropriate plated-through holes for improving the vertical heat conduction, so-called thermal vias, can expediently also be provided in the sub-circuit board in place of the attached light sources.

It can be particularly economical if a method according to the invention is used in a motor vehicle headlight according to the invention, a multilayer standard printed circuit board being provided as the printed circuit board, in which at least one sub-printed circuit board is at least partially separated from the main printed circuit board by means of milled exemptions and in which the structure of the flexible circuit board section has fewer layers or layers in comparison to the base circuit board and / or the at least one sub-circuit board.

The production of corresponding exemptions, for example by means of deep milling on a multi-layer standard printed circuit board, in order to create one or more flexibly movable sub-printed circuit boards within the printed circuit board is inexpensive.

It can be disadvantageous here that the printed circuit board in the area of the exposed sub-printed circuit boards has reduced stability up to assembly in the installed position within the motor vehicle headlight.

In order to further simplify the assembly process with light sources and also to increase the stability and reliability of the printed circuit boards, such a standard printed circuit board is preferably provided, in which at least one securing web is provided, which is arranged in the area of the release and the basic printed circuit board and the base - Connects the circuit board with the at least one sub-circuit board, which is equipped with at least one light source, and secures the at least one assembled sub-circuit board in a starting position in the plane of the circuit board. The at least one securing web can particularly preferably be severed together with the release of the panel separation joints, for example by means of a milling tool.

With the method according to the invention, a particularly cost-effective and flexible assembly or alignment method is specified, which allows individual light sources arranged on sub-printed circuit boards in the most cost-effective manner possible, each in an individual, coordinated positioning relative to one another

To mount the vehicle headlight housing.

The invention will be explained in more detail using exemplary embodiments with reference to the schematic drawings. Show it: - Fig. 1 in a sectional view from the side a detail of an inventive

Motor vehicle headlamp with a plurality of sub-printed circuit boards fixed in an inclined position, the light beams emitted by the light sources being oriented in the direction of an optical system;

2A in a sectional view from the side a detail of an inventive

Motor vehicle headlights with a sub-circuit board fixed in an inclined position;

2B is a top view of the arrangement shown in FIG. 2A;

3 shows a sectional view of a sub-circuit board tilted relative to the base circuit board;

4A to 4E each show individual steps in the production of a sub-printed circuit board within a standard multilayer printed circuit board, the illustrations in FIGS. 4A to 4C each showing top views and the two illustrations in FIGS. 4D and 4E the sub-printed circuit board in an isometric view Show oblique view from the front;

5 is an isometric oblique view from the front of another according to the invention

Variant in which a sub-circuit board is attached in an inclined position to a support body with the aid of a holding device;

6 is an isometric oblique view from the front of an alternative according to the invention

Variant in which a sub-circuit board is attached in an inclined position to a holding device of a carrier body.

The assignment of terms with regard to their location or their orientation, such as, for example, “horizontal”, “vertical”, “in the horizontal direction”, “in the vertical direction”, “above”, “below”, “in front”, “below”, “ above "etc. are chosen in the following description only for the sake of simplicity and may refer to the illustration in the drawings, but not necessarily to a position in use or installation of the lighting device or the motor vehicle headlight.

1 shows a detail of a motor vehicle headlight 1 according to the invention with a plurality of light sources 10, each of which has a light-emitting surface 11 here. Of the

Motor vehicle headlights 1 further include an optical system 20, which here has, for example, an optical lens 21. The light sources 10 are set up to emit generated light from the light-emitting surfaces 11 in the main light beam directions Si, S2 outlined as dash-dotted arrows Si, S2 of the optical system 20. The optical system 20 is set up to emit light in the light beam direction S outlined as a dash-dotted arrow S onto a roadway.

The circuit board 30 used here comprises a base circuit board 31, flexible

Printed circuit board sections 32 and two sub-printed circuit boards 33 each equipped with a light source 10. The flexible printed circuit board sections 32 are located between the base Printed circuit board 31 and the sub-circuit boards 33 and connect them movably to the base circuit board. Furthermore, a carrier body 40 is provided, which is arranged on the underside of the sub-printed circuit boards 33, that is to say on those rear sides facing away from or opposite the light sources 10 on the upper side of the sub-printed circuit boards 33. Of the

Carrier body 40 is designed in such a way that it can be connected at least in sections to the sub-circuit boards 33 and is designed to, in a position connected to the sub-circuit board 33 - as illustrated here in FIG. 1 - the sub-circuit boards 33 in pivoted positions to fix, the pivoted positions can be set at individually adjustable inclination angles α, β relative to the plane of the base circuit board 31.

The first light source 10 is shown on the right in the image of FIG. 1, which is fixed in an inclined position at an angle of inclination a, measured between the right sub-printed circuit board 33 and the base printed circuit board 31, lying on a corresponding contact surface 41 of the carrier body 40. On the left in the image of FIG. 1, the second light source 10 is shown, which, in an inclined position at an inclination angle β, measured between the left sub-circuit board 33 and the base circuit board 31, also on a corresponding one

Support surface 41 of the support body 40 is fixed lying on. The carrier body 40 is designed here in one piece, for example, and is manufactured as a heat sink 45 from a heat-conducting material. In order to achieve a good heat-conducting fastening between the support surfaces 41 of the carrier body 40 or here the heat sink 45 and the sub-circuit boards 33 lying thereon, these are each glued to the support surfaces 41 with a heat-conducting adhesive layer 50. The carrier body 40 here has two ramp-shaped or wedge-shaped elevations, which protrude from the inclined angles α, β with respect to an upper side of the otherwise flat or flat carrier body 40. Using the carrier body 40, the two sub-printed circuit boards 33 equipped with light sources 10 can thus be fixed in such a way that the light generated below them

Inclination angles a, β - relative to the plane of the base circuit board 31 - are emitted by the light sources 10 and the emitted light beams or main light beam directions of the light sources 10 can be aligned in the direction of the optical system 20.

1, a multilayer standard printed circuit board is used as the printed circuit board 30 here, in which the sub-printed circuit boards 33 are separated from the main printed circuit board 31 in sections by means of milled exemptions 35 and in which the flexible printed circuit board section 32 is compared to the basic printed circuit board 31 and the sub-circuit boards 33 has fewer layers or layers.

1 shows a schematic view of a motor vehicle headlight 1 according to the invention with its components essential for the explanation of the invention. It is clear to the person skilled in the art that a motor vehicle headlight has a large number of others, here May have components not shown, such as setting and adjustment devices, electrical supply means, panels, housing components and much more. If the term “headlight” is used in connection with the invention, this term should also include individual light or projection modules, which can also be contained in combination in a higher-level headlight.

The two views of FIGS. 2A and 2B are common below

discussed. A detail of a motor vehicle headlight 1 according to the invention with a sub-circuit board 33, which is fixed in a position inclined at an angle of inclination a, is shown. The one light source 10 of the assembled sub-circuit board 33 can be in the arrow direction Bi to identify the direction of movement from a first position in which the sub-circuit board 33 equipped with the at least one light source 10 and the at least one carrier body 40 are separated from one another in an unconnected position. are transferred along a spatial movement path, in particular by tilting, pivoting and / or rotating, into the second position shown here, in which the sub-circuit board 33 equipped with the light source 10 and the at least one carrier body 40 are fixed to one another in a connected position. The first position or starting position is not shown here for the sake of clarity. The optical system 20 used here is, for example, a schematically indicated reflector 22. Openings 35 on three sides between the sub-printed circuit board 33 and the basic printed circuit board 31 surrounding it and the removal of layers in the area of the flexible printed circuit board section 32 ensure a flexibly movable adjustment of the Inclination of the sub-circuit board 33 thus exposed. The light generated, which is emitted from the light source 10 at the angle of inclination a, can be oriented in the direction of the optical system 20.

In Fig. 3, a multilayer standard circuit board is shown as the circuit board 30, in which the sub-circuit boards 33 are separated in sections from the base circuit board 31 by means of milled exemptions 35 and in which the structure of the flexible circuit board section 32 in comparison to the base circuit board 31 and the sub-circuit boards 33 has fewer layers or layers. The sub-circuit board 31 is not yet connected to a carrier body and its inclination with respect to the plane of the base circuit board 31 can thus be moved back and forth in the direction of the arrow Bi to identify the direction of movement. In this way, for example, an individual angle of inclination a can be set and fixed in its inclined position by contact with one or more corresponding support bodies.

FIGS. 4A to 4E each show individual steps in the production of a sub-printed circuit board 33 within a standard multilayer printed circuit board 30. In order to further simplify the assembly process with light sources 10 and also to increase the stability and reliability of the printed circuit boards used, it is preferred a Standard circuit board 30 is provided, in which at least one securing web 36 is provided, which, in the area of the clearance 35, the base circuit board 31 and the at least one sub-circuit board 33, which is equipped with at least one light source 10, during the assembly with the corresponding ones connects optical and / or electronic components. The securing web 36 shown here in FIG. 4A thus secures the already assembled sub-printed circuit board 33 in its starting position in the plane of the printed circuit board 30 or in the plane of the surrounding basic printed circuit board 31. For example, the securing web 36 can only be used for a short time before or also only be cut during assembly of the base circuit board 31 in its installed position within the motor vehicle headlight 1, which is illustrated in FIG. 4B. For this purpose, the securing web 36 is severed with a separating tool 37 or here with a milling cutter in the direction of movement 38 of the separating tool 37 - symbolized by the arrow 38. FIG. 4C already shows the area of the sub-printed circuit board 33 which is correspondingly free on three sides. The two figures FIGS. 4D and 4E show the pivoting of the assembled sub-printed circuit board 33 in the direction of movement Bi until an individual inclination angle a with respect to the plane the base circuit board 31 is set. A carrier body (not shown here) and / or corresponding holding devices, which are expediently connected to the carrier body, can subsequently serve to fix the tilted position of the inclined sub-printed circuit board 33 and to fix the radiation angle of the light beams from the light source 10.

With the alignment method according to the invention, a particularly inexpensive and flexible assembly method is specified, which allows individual light sources 10 arranged on sub-printed circuit boards 33 in the most cost-effective manner in each case in individual, coordinated positioning and at individual angles of inclination - in deviation from a coplanar mounting position or alignment on the base circuit board - to be mounted relative to one another in a vehicle headlight housing 1.

Fig. 5 shows a further variant of the invention, in which a sub-circuit board 33 in an inclined position at an inclination angle g relative to the base circuit board 31 is attached to a carrier body 40 in the form of a heat sink 45. The carrier body 40 has a flat bearing surface 41 which bears against the rear or underside of the sub-circuit board 33 and to which the sub-circuit board 33 is glued with a heat-conducting adhesive layer 50. In addition, here is a holding device 55 in the form of a

Clamping bracket 56 is provided, which fixes the sub-circuit board 33 together with the heat sink 45 adhered to it in its inclined position.

Fig. 6 shows another alternative fiction, contemporary variant, in which a sub-circuit board 33 in an inclined position at an angle of inclination d relative to the base circuit board 31 is attached to a support body 40 in the form of a heat sink 45. The carrier body 40 is made of several parts here, is also partially invisible below the level of the basic Printed circuit board 31 is arranged and has a holding device 55 in the form of a tiltably mounted screw holder 57, which is fastened to the underside of the heat sink 45 of the sub-printed circuit board 33 and to the carrier body 40 and which fixes the sub-printed circuit board 33 in an inclined position at the angle of inclination d . The heat sink 45 is here articulated to the multi-part carrier body 40. With such a screw holder 57, the angle of inclination of the light source 10 on the sub-circuit board 33 can advantageously be fine-adjusted if necessary, without having to replace the carrier body 40.

LIST OF REFERENCES

1 motor vehicle headlight

10 light source

11 Light-emitting surface of the light source

20 optical system

21 optical lens

22 reflector

30 circuit board

31 Basic circuit board

32 flexible circuit board section

33 sub-circuit board

35 Exemption between sub-circuit board and base circuit board

36 safety bar

37 Cutting tools, milling cutters

38 direction of movement of the separating tool (arrow)

40 carrier bodies

41 contact surface of the carrier body p

45 heat sinks

50 adhesive layer

55 holding device

56 Clamp bracket

57 screw holder

Bi direction of movement (double arrow)

Si main light beam direction from the (first) light source (arrow)

S ₂ main light beam direction from another light source (arrow)

Direction of light rays from the optical system (arrow)

a Inclination angle between the (first) sub-circuit board and the base circuit board

Inclination angle between further sub-printed circuit boards and basic printed circuit board

Claims

PATENT CLAIMS

1. Motor vehicle headlight (1) with at least one light source (10) which is arranged on a printed circuit board (30) and with at least one optical system (20), the at least one light source (10) having a light-emitting surface (11) and is set up to emit generated light from the light-emitting surface (11) in the direction (Si) of the optical system (20), and the optical system (20) is set up to emit light in a desired beam direction (S) as on a roadway , wherein the printed circuit board (30) has a basic printed circuit board (31), at least one sub printed circuit board (33) equipped with the at least one light source (10) and at least one flexible printed circuit board section (32) which contains the basic printed circuit board (31) movably connects to the at least one sub-circuit board (33), the sub-circuit board (33) being connectable, at least in sections, to at least one carrier body (40) and the at least one carrier body (40) is set up in a position connected to the sub-circuit board (33) to fix the at least one sub-circuit board (33) in a position pivoted at an inclination angle (a) relative to the base circuit board (31), wherein the generated light is emitted from the at least one light source (10) at this angle of inclination (a),

characterized in that

the printed circuit board (30) is a multilayer standard printed circuit board, in which at least one sub-printed circuit board (33) is at least partially separated from the base printed circuit board (31) by means of milled exemptions (35) and in which the flexible one

Printed circuit board section (32) has fewer layers or layers in comparison to the basic printed circuit board (31) and / or the at least one sub-printed circuit board (33).

2. Motor vehicle headlight (1) according to claim 1, characterized in that the at least one light source (10) from a first position in which the at least one light source (10) equipped sub-circuit board (33) and the at least one carrier body ( 40) are separated from one another in an unconnected position, along a spatial movement path, in particular by tilting, pivoting and / or rotating into a second position in which the sub-circuit board (33) equipped with the light source (10) and the at least one carrier body (40 ) are fixed together in a connected position, can be transferred.

3. Motor vehicle headlight (1) according to one of claims 1 or 2, characterized

characterized in that in the fixed position of the sub-circuit board (33) equipped with the at least one light source (10) and in which the sub-circuit board (33) is pivoted relative to the base circuit board (31) at an inclination angle (a) the at least one carrier body (40) is connected, which is aligned by the at least one light source (10) emitted main light beam direction (Si) in the direction of the at least one optical system (20).

4. Motor vehicle headlight (1) according to one of claims 1 to 3, characterized

characterized in that in the fixed position pivoted at an angle of inclination (a) relative to the base circuit board (31) of a sub-circuit board (33) equipped with a plurality of light sources (10), in which the sub-circuit board (33) with the at least a carrier body (40) is connected, which are aligned by the plurality of light sources (10) emitted main light beam directions (Si, S2) in the direction of the at least one optical system (20).

5. Motor vehicle headlight (1) according to one of claims 1 to 4, characterized

characterized in that the printed circuit board (30) has a plurality of sub-printed circuit boards (33) each equipped with at least one light source (10), which are provided with flexible

Circuit board sections (32) are movably connected to the main circuit board (31), the plurality of sub-circuit boards (33) equipped with light sources (10) each at individual angles of inclination (a, β, g, d) relative to the main circuit board (31) pivoted, fixed layers with the at least one

Carrier body (40) are connected.

6. Motor vehicle headlight (1) according to one of claims 1 to 5, characterized

characterized in that the circuit board (30) has a plurality of sub-circuit boards (33) each equipped with at least one light source (10), which are arranged in a matrix-like manner with respect to one another, the plurality of sub-circuit boards (33) equipped with light sources (10) each in below individual angles of inclination (a, β, g, d), fixed layers pivoted relative to the base circuit board (31) are connected to the at least one carrier body (40).

7. Motor vehicle headlight (1) according to one of claims 1 to 6, characterized

characterized in that the motor vehicle headlight (1) comprises at least two optical systems (20), at least one first sub-circuit board (33) equipped with light sources (10) at a first inclination angle (a) relative to the base circuit board (31) pivoted, fixed position is connected to the at least one carrier body (40) and the main light beam direction (Si) emitted by the at least one light source (10) is oriented in the direction of a first optical system (20), and at least a second one with light sources (10) Equipped sub-circuit board (33) in a fixed position with the at least one carrier body pivoted at a second inclination angle (β) relative to the base circuit board (31) (40) is connected and the main light beam direction (Si) emitted by the at least one light source (10) is oriented in the direction of a second optical system (20).

8. Motor vehicle headlight (1) according to one of claims 1 to 7, characterized

characterized in that the at least one carrier body (40) has at least one

Has contact surface (41) on which at least one sub-circuit board (33) equipped with the light source (10) is fastened in its position connected to the carrier body (40).

9. Motor vehicle headlight (1) according to one of claims 1 to 8, characterized

characterized in that the at least one support body (40) is designed as a heat sink (45) and the at least one sub-circuit board (33) equipped with the light source (10) is in heat-conducting contact with the at least one support surface (41) of the support body (40), preferably with a heat-conducting adhesive layer (50).

10. Motor vehicle headlight (1) according to one of claims 1 to 9, characterized

characterized in that the carrier body (40) has at least one holding device (55) with which the at least one sub-circuit board (33) equipped with the light source (10) is positioned at an angle of inclination (a) relative to the base circuit board (31) ver pivoted position on the support body (40) can be fixed, preferably with the holding device (55) the angle of inclination (a) of the attached sub-circuit board (33) is adjustable.

11. Motor vehicle headlight (1) according to one of claims 1 to 10, characterized

characterized in that the at least one light source (10) arranged on the sub-printed circuit board (33) is designed as an SMD LED module, as a COB LED module or as an MCOB LED module.

12. A method for aligning at least one light source (10)

Motor vehicle headlight (1) in the direction of an optical system (20), the at least one light source (10) having at least one light-emitting surface (11) and being set up to emit generated light from the light-emitting surface (11), comprising the following steps:

Providing a circuit board (30) with a base circuit board (31), with at least one sub-circuit board (33) which is equipped with at least one light source (10), and with at least one flexible circuit board section (32) which Printed circuit board (31) movably connects to the at least one sub-printed circuit board (33), the printed circuit board (30) being a multi-layer standard printed circuit board in which the at least one sub-circuit board (33) is at least partially separated from the base circuit board (31) by means of milled exemptions (35) and in which the flexible circuit board section (32) compared to the base circuit board (31) and / or the at least one Sub-circuit board (33) has fewer layers or layers;

Providing at least one carrier body (40), which is set up to, in a position connected to the sub-circuit board (33), the at least one sub-circuit board (33) at an angle of inclination (a) relative to the base circuit board (31) fix swiveled position;

Transferring the at least one sub-circuit board (33) equipped with a light source (10) along a spatial movement path, in particular by tilting, pivoting and / or rotating into a position pivoted relative to the base circuit board (31) at an angle of inclination (a) which the at least one sub-circuit board (33) abuts at least in sections on the at least one carrier body (40) and / or on at least one holding device (55) of the carrier body (40);

Fixing the at least one sub-circuit board (33) equipped with a light source (10) to the at least one carrier body (40) in a position pivoted at an angle of inclination (a) relative to the base circuit board (31), the position of the at least one Light source (10) generated light is emitted at this inclination angle (a) from the at least one light source (10) in the direction of the opulent system (20);

Mounting the printed circuit board (30) together with the at least one carrier body (40), which is fastened to the at least one sub-printed circuit board (33), in the installed position within the motor vehicle headlight (1).

13. The method according to claim 12, characterized in that the circuit board (30)

has a plurality of sub-printed circuit boards (33) each equipped with at least one light source (10), which are movably connected to the base printed circuit board (31) by flexible printed circuit board sections (32), the plurality of sub-printed circuit boards (32) equipped with light sources (10) 33) are each connected to the at least one carrier body (40) in fixed positions pivoted at individual angles of inclination (a, β, g, d) relative to the base circuit board (31), as well as those of the at the several sub- Printed circuit boards (33) arranged light sources (10) emitted

Main light beam directions (Si, S2) are aligned in the direction of the at least one optical system (20).

14. The method according to claim 13, characterized in that the

Motor vehicle headlight (1) comprises at least two optical systems (20), wherein at least one first sub-circuit board (33) equipped with a light source (10) at a first inclination angle (a) relative to the base circuit board (31)

ver pivoted, fixed position is connected to the at least one support body (40), the main light beam direction (Si) emitted by the light source (10) arranged on this sub-circuit board (33) being oriented in the direction of the first optical system (20) , and at least one second sub-printed circuit board (33) equipped with a light source (10) is connected to the at least one carrier body (40) in a fixed position pivoted at a second inclination angle (β) relative to the base printed circuit board (31), wherein the main light beam direction (S2) emitted by the light source (10) arranged on this sub-printed circuit board (33) is aligned in the direction of the second optical system (20).

15. The method according to any one of claims 12 to 14, characterized in that the at least one carrier body (40) is designed as a cooling body (45) and the at least one sub-circuit board (33) equipped with the light source (10) on at least one contact surface (41) of the carrier body (40) is attached in a heat-conducting manner, preferably with a heat-conducting adhesive layer (50), in a pivoted, fixed position.

16. The method according to any one of claims 12 to 15, characterized in that

at least one securing web (36) is arranged in the area of the clearance (35), the at least one securing web (36) the base circuit board (31) and the at least one sub-circuit board (33), which are connected to at least one light source (10) is assembled, connects to one another and secures the at least one assembled sub-circuit board (33) in an initial position in the plane of the circuit board (30).