EP4481268A1

EP4481268A1 - An optical device for an automotive vehicle and method of assembly thereof

Info

Publication number: EP4481268A1
Application number: EP23180690.2A
Authority: EP
Inventors: Santhosh PARTHASARATHY; Etienne SILL
Original assignee: Valeo Vision SAS
Current assignee: Valeo Vision SAS
Priority date: 2023-06-21
Filing date: 2023-06-21
Publication date: 2024-12-25

Abstract

The present invention pertains to an optical device (100) for a vehicle comprising a light source (10) configured to produce a light beam. The optical device (100) further comprises light guides (20, 20') having light entry portions (22, 22') that are arranged facing the light sources (10) to receive said light beam. The optical device (100) further comprises a support structure (30) configured to support the light guide (20). A double cover assembly (40) is mounted on the support structure (30) such that an inner cover (42) covers the light entry portion (22) of a first light guide (20) and an outer cover (44) covers the light entry portion (22') of a second light guide (20'). The outer cover (44) is pivotally connected to the inner cover (42) and a locking mechanism (60) is provided to secure a free end of the outer cover (44) to the inner cover (42).

Description

TECHNICAL FIELD OF THE INVENTION

The present invention relates to an optical device for an automotive vehicle, and more particularly to an optical device having a double cover assembly to cover a part of the optical device.

BACKGROUND OF THE INVENTION

Optical devices are used in automobiles and the like, for lighting the path ahead and also for providing signaling functions. These lighting functions include low beam light, high beam lights, turn indicator, parking/position lamp, tail/ stop lamp, day running lights (DRL), fog lamp and/ or signature lamp. Most of the modern optical devices use light guides that are attached facing one or more light sources. The light produced by these light sources enters the light guide through a light entry portion and is propagated through the light guide by multiple total internal reflection. In optical devices having more than one lighting functions, different light guides each associated with a specific function may be provided, for example individual light guides associated with an amber light source and a white light source for turn indicator and DRL function respectively may be provided.
The optical devices using light guides are known to be affected by light leakage issues. The leakage may affect the optical efficiency of the optical device further affecting the lighting function as well. It is paramount in optical devices disclosed above (specifically having multiple light guides) that the light from one light guide does not leak to the other light guide. Also any undesired leakage of light from the light guide towards outside needs to be prevented. The leakage may affect the lighting functionality and may create a safety issue due to light mixing, especially light color mixing and undesired exposure of the light guide. Further, the light leakage may affect the visual styling of the vehicle headlamp which may be perceived negatively by the user. Some optical devices may be designed such that the light guides need to cross each other in a physical plane. This crossing of light guides is needed in order to fulfill the requirements pertaining to light guide curvature and also to meet regulation. In such optical devices the light leakage is a huge issue and may aggravate the above disclosed issues.
To overcome the said issues some optical modules are provided with a cover that are configured to cover a portion of the light guide. These covers are usually fixed to the housing or a mask by means of clipping structures such as press clips or snap fit clips. However they are not effective in preventing light leakage between multiple light guides and light leakage from light guides towards outside in the optical devices. Further, the cover having clipping structures may involve assembly constraints and may not be able to properly fit to the housing and may not be able to arrest the movement of the cover during harsh vehicle operation conditions leading to failure.
The prior art and the conventional methods have various disadvantages as described earlier and there is a need for an optical device that can overcome the issues of the prior art to prevent light leakage between the light guides and also from the light guides towards outside.

SUMMARY OF THE INVENTION

An object of the present invention is to solve the disadvantages described above of known optical devices.
In particular, the object of the present invention is to provide an optical device that can prevent light leakage between the light guides and from light guides towards outside of the optical device.
In an embodiment of the present invention, an optical device for an automotive vehicle comprises: at least one light source configured to produce a light beam, at least one light guide configured to propagate said light beam. The at least one light guide includes a light entry portion arranged facing the at least one light source to receive said light beam. Further, the optical guide comprises at least one support structure configured to support the at least one light guide, and at least one double cover assembly mounted on at least one support structure, configured to cover the light entry portion of the at least one light guide. An inner cover of the at least one double cover assembly and the at least one support structure may create a hinge in an assembled state, further, the hinge is configured to rotatably secure the at least one double cover assembly and the at least one support structure around a hinge axis. The double cover assembly is arranged over the light entry portions of the light guides thus masking light leakage from the said face of the light guide from being visible. Further, an outer cover of the double cover assembly covers at least a portion of a second light guide thus preventing leakage of the light from the second light guide towards outside.
In an embodiment of the present invention, the at least one double cover assembly comprises an inner cover hingedly mounted on the at least one support structure such that the inner cover can be rotated to cover the light entry portion of the at least one light guide. The at least one double cover assembly further comprises an outer cover pivotally connected to the inner cover at a predetermined edge to cover at least a portion of the second light guide.
In an embodiment of the present invention, the outer cover is configured to be secured to the inner cover by a locking mechanism.
In an embodiment of the present invention, the outer cover is configured to be integrally formed with the inner cover and a connecting portion is formed between them to allow the rotation of the outer cover relative to the inner cover. The thickness of the connecting portion is reduced or lower or less than the thickness of the inner cover and the outer cover, to provide flexibility to said connection portion. As the connecting portion is made flexible, the outer cover can be rotated with respect to the inner cover to prevent light leakage from at least one light guide placed between the inner cover and the outer cover, towards the outside.
In an embodiment of the present invention, the connecting portion is configured to be formed continuously along the edges of the outer cover and the inner cover.
In an alternate embodiment of the present invention, the connecting portion is configured to be formed intermittently along the edges of the outer cover and the inner cover, to allow the rotation of the outer cover relative to the inner cover. Thus, the connecting portion comprises multiple bridge sections having reduced or lower or less thickness, compared to the thickness of the inner and outer cover. The connecting portion is made flexible to allow relative rotation between the outer cover and the inner cover. In the context of the invention, flexible means that the connecting portion is adapted to be folded, between an open configuration and a closed configuration of the outer cover, without being damaged or broken. In the open configuration of the outer cover, the outer cover is pivoted away from the inner cover.
In an alternate embodiment of the present invention, the outer cover is configured to be pivotally connected to the inner cover through hinges or straps.
In an alternate embodiment of the present invention, any suitable pivot joint can be used to connect the outer cover with the inner cover.
In an embodiment of the present invention, the outer cover is configured to be pivotally connected to a top edge of the inner cover.
In an alternate embodiment of the present invention, the outer cover is configured to be pivotally connected to a bottom edge of the inner cover.
In an embodiment of the present invention, the outer cover is configured to be rotated over the second light guide and secured with the inner cover by a locking mechanism.
In an embodiment of the present invention, the locking mechanism comprises any of a press-fit mechanism or a snap-fit mechanism or hooks or glue tape or any similar connection means.
In an embodiment of the present invention, the optical device comprises at least two light guides and at least two light sources, and further, each of the light guides is arranged facing respectively one of the at least two light sources. Each of the light guides along with the respective light sources may enable using different lighting functions such as turn indicator and day running light functions. In an alternate embodiment, the optical device may include a single light guide arranged facing a single or plurality of light sources. In said configuration, the optical device may be configured to perform a single lighting function or different lighting functions.
In an embodiment of the present invention, a method of assembling at least one double cover assembly, according to the present invention, on at least one support structure of an optical device is envisioned, said assembly process comprises the steps of mounting a first light guide on the at least one support structure of the optical device, further, a light entry portion of the first light guide is arranged facing a light source. The assembly process further comprises the step of mounting at least one double cover assembly on said support structure wherein an inner cover of the double cover assembly is configured to be hingedly mounted on the at least one support structure to cover the light entry portion of the at least one light guide.
In an embodiment of the present invention, the assembly process further comprises a step of mounting a second light guide over the inner cover of the at least one double cover assembly. The second light guide assembled over the inner cover enables the light guides to be placed on the opposite sides of the inner cover, thus preventing light leakage between the two light guides.
In an embodiment of the present invention, the assembly process further comprises a step of rotating an outer cover of the at least one double cover assembly to cover the light entry portion of the second light guide, thus preventing light leakage from the light entry portion of the second light guide towards outside.
In an embodiment of the present invention, the assembly process further comprises a step of securing the outer cover with the inner cover by a locking mechanism. The locking mechanism can be any of a clipping structure, a press-fit mechanism, a snap-fit assembly, hooks or glue tape.
The assembly process allows an easy and secure assembly of the double cover assembly on the support structure and further prevents light leakage from the light guides.

BRIEF DESCRIPTION OF DRAWINGS

To complete the description and to provide a better understanding of the invention, a set of drawings is provided. Said drawings form an integral part of the description and illustrate an embodiment of the invention, which should not be construed as restricting the scope of the invention, but only as an example of how the invention can be carried out. The drawings comprise the following characteristics.

Figure 1 shows a perspective view of an optical device comprising a double cover assembly, according to an embodiment of the present invention;
Figure 2 shows a perspective view of the optical device of Figure 1 showing the light guide arrangement without the double cover assembly, according to an embodiment of the present invention;
Figure 3A shows a front perspective view of a double cover assembly, according to an embodiment of the present invention;
Figure 3B shows a rear perspective view of a double cover assembly, according to an embodiment of the present invention; and
Figures 4A - 4E show sequential steps of the assembly process of the optical device, according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.
Figure 1 shows an optical device 100 for an automotive vehicle according to an embodiment of the present invention. The optical device 100 of the present invention comprises at least one light source 10 (as seen in Figure 2) configured to produce a light beam. The light beam produced by the light sources 10 may be used for various lighting functions such as low beam light, high beam lights, turn indicator, parking/position lamp, tail/ stop lamp, day running lights (DRL), fog lamp and/ or signature lamp. In said optical device 100, the light sources 10 may be of amber and white color respectively, to achieve the above said functions. Alternatively, the light sources 10 may be of red color to achieve stop lamp or tail lamp function, further, the light sources 10 may be adapted to achieve fog lamp function as well. Further as shown in Figure 2, the optical device 100 may comprise at least one light guide 20 configured to propagate said light beam. In addition, the at least one light guide 20 includes a light entry portion 22 arranged facing the at least one light source 10 to receive said light beam. The light beam that enters the at least one light guide 20 through the light entry portion 22 may be propagated towards a light exit portion (not shown) of the light guide 20 by means of multiple total internal reflection. The light beam exiting from said exit portion may be viewable from outside the optical device 100 to carry out the desired lighting function.
Light guides are usually supported by a light guide support structure which may be further supported on a housing of the optical device. In some cases the support structure may also function as a mask that may be configured to mask other components of the optical device. In an embodiment of the present invention, as seen in Figure 2, the optical device 100 further comprises at least one support structure 30 configured to support the at least one light guide 20. The support structure 30 may allow supporting the at least one light guide 20 with respect to the light sources 10. The light guide 20 is arranged such that optimal distance is maintained between the light sources 10 and the at least one light guide 20. The optimal distance signifies the best possible position of the light guide with respect to the light sources so as to allow optimized or maximized amount of light beam produced by the light source 10 transmitted through the entry portion 22.
In addition, the optical device 100 may comprise at least one double cover assembly 40 that is mounted on the at least one support structure 30 and may be configured to cover the light entry portion 22 of the at least one light guide 20. The at least one double cover assembly 40 is a physical structure or part that may be assembled over the specific portion of the light guide 20 so that the light guide may not be visible from outside the optical device 100.
In a preferred embodiment as shown in Figures 3A and 3B, the at least one double cover assembly 40 comprises an inner cover 42 to be hingedly mounted on the at least one support structure 30. The at least one double cover assembly 40 further comprises an outer cover 44 pivotally connected to the inner cover 42. A locking mechanism 60 is provided to secure the free end of the outer cover 44 with the inner cover 42. In assembled condition, the light guides 20, 20' are placed on the opposite sides of the inner cover 42, thus preventing light leakage between a first light guide 20 and a second light guide 20'. Further, the outer cover 44, when closed, masks at least a portion of the second light guide 20' to prevent light leakage from the light entry portion 22' of the second light guide 20' towards outside. Thus the light entry portions 22, 22' of the light guides 20, 20, will not be visible from outside. The outer cover 44 is secured in its closed state, to the inner cover 42 by a press-fit mechanism or a snap-fit mechanism or hooks or glue tape or any similar connection means.
In an embodiment of the present invention, the outer cover 44 and the inner cover 42 are integrally formed as a single part. A continuous connecting portion 43 may be formed between the inner cover 42 and the outer cover 44 to allow the pivoting motion of the outer cover 44. Alternatively, intermittent bridges of the connecting portions may be formed between the inner cover 42 and the outer cover 44. The thickness of the connecting portion 43 is lower or less than the thickness of the inner cover 42 and the outer cover 44 allowing the connecting portion 43 to be flexible. The flexibility of the connecting portion 43 allows the outer cover 44 to be rotated with respect to the inner cover 42 to cover the light entry portion 22' of the second light guide 20' positioned between the inner cover 42 and the outer cover 44.
In an embodiment of the present invention, the outer cover 44 may be pivotally connected to a top edge 422 or a bottom edge 424 of the inner cover 42. Here, the top and bottom must be understood as in the normal mounting orientation of the double cover assembly 40 on the vehicle.
In an embodiment of the present invention, the double cover assembly is made from plastic or any suitable material.
In an alternate embodiment of the present invention, the outer cover 44 and the inner cover 42 may be pivotally connected through hinges or straps.
In a preferred embodiment, the optical device 100 comprises at least a first light guide 20, and a second light guide 20', configured to propagate light from at least two light sources 10. As described earlier, the two light guides 20, 20' may be associated with two light sources 10 such as amber color light source and white color light source for enabling turn indicator function and day running light function respectively. More in detail, the first light guide 20 is associated with an amber color light source, and the second light guide 20' is associated with an white color light source, or opposite. Alternatively, both light guides may be associated respectively with at least one amber color light source and one white color light source. In said embodiment, the at least one double cover assembly 40 comprises an inner cover 42 hingedly mounted on the support structure 30 and an outer cover 44 pivotally connected to the inner cover 42 through a connecting portion 43. In an exemplary embodiment of the present invention, the first light guide 20 and the second light guide 20' are assembled on opposite sides of the inner cover 42 and the outer cover 44 is closed to cover at least some portion of the second light guide 20'. As the light guides 20, 20' are on opposite sides of the inner cover 42, the light from the first light guide 20 does not leak into the second light guide 20', and the light from the second light guide 20' does not leak into the first light guide 20. Further, as the outer cover 44 is closed to cover at least some portion of the second light guide 20', the light from the entry portion 22' of the second light guide 20' does not leak to the outside.
A process for assembling the at least one double cover assembly 40 on at least one support structure 30 of an optical device 100 according to an embodiment of the present invention is described with reference to Figures 4A - 4E. Figure 4A illustrates at least one support structure 30 at the initial step of assembly. The assembly process comprises the steps of providing a first light guide 20 on the at least one support structure 30 of the optical device 100. The first light guide 20 is provided such that a light entry portion 22 of the first light guide 20 is arranged facing a light source 10. The distance between the first light guide 20 and the light source 10 may be maintained such that an optimized or maximized amount of light beam produced by the light source 10 is transmitted through the entry portion 22. Further, at least one double cover assembly 40 may be provided on said support structure 30 such that an inner cover 42 of the double cover assembly 40 covers the light entry portion 22 of the first light guide 20. The inner cover 42 of the at least one double cover assembly 40 may be configured to form a hinge with the at least one support structure 30. At this stage, an outer cover 44 of the double cover assembly 40 is in open configuration, as shown in Figure 4C, wherein the free end of the outer cover 44 is away from the inner cover 42.
Further, the assembly process comprises a step of providing a second light guide 20' over the inner cover 42 of the at least one double cover assembly 40. The second light guide 20' may be provided on the opposite side of the inner cover 42 as compared to the first light guide 20. Similar to the first light guide 20, light entry portion 22' of the second light guide 20' is arranged facing another light source 10. In addition, the inner cover 42 of the at least one double cover assembly 40 may be secured on the support 30 using clipping structures that are configured to mate with locking structures of the at least one support structure 30. Further, the outer cover 44 of the double cover assembly 40 is rotated from its open configuration to closed configuration, about a flexible connecting portion 43 to cover the light entry portion 22' of the second light guide 20'. Further, the outer cover 44 is secured to the inner cover 42 by locking a free end of the outer cover 44 on the inner cover 42 by a locking mechanism 60.
Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. Plural structural components can be provided by a single integrated structure. Alternatively, a single integrated structure might be divided into separate plural components. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention.

LIST OF REFERENCE NUMERALS

Reference Number	Description
10	light source
20	light guide
22	light entry portion
30	support structure
40	double cover assembly
42	Inner cover
43	connecting portion
44	outer cover
60	locking mechanism
100	optical device
422	top edge of the inner cover
424	bottom edge of the inner cover

Claims

An optical device (100) for an automotive vehicle comprising:
at least one light source (10) configured to produce a light beam;

at least one light guide (20) configured to propagate said light beam, wherein the at least one light guide (20, 20') includes a light entry portion (22, 22') arranged facing the at least one light source (10) to receive said light beam;

at least one support structure (30) configured to support the at least one light guide (20, 20'); and

at least one double cover assembly (40) mounted on the at least one support structure (30), configured to cover the light entry portion (22, 22') of the at least one light guide (20);

characterized in that the at least one double cover assembly (40) comprises an inner cover (42) configured to be hingedly mounted to the at least one support structure (30), and an outer cover (44) configured to be pivotally connected to a predetermined edge of the inner cover (42).
The optical device (100) according to claim 1, wherein the outer cover (44) is configured to be secured to the inner cover (42) by a locking mechanism (60).
The optical device (100) according to any of claims 1 to 2 , wherein the outer cover (44) is configured to be integrally formed with the inner cover (42) and a connecting portion (43) is formed between them, wherein the thickness of the connecting portion (43) is less than the thickness of the inner cover (42) and the outer cover (44).
The optical device (100) according to claim 3, wherein the connecting portion (43) is configured to be formed continuously along the edges of the outer cover (44) and the inner cover (42).
The optical device (100) according to claim 3, wherein the connecting portion (43) is configured to be formed intermittently along the edges of the outer cover (44) and the inner cover (42).
The optical device (100) according to claim 1 or claim 2, wherein the outer cover (44) is configured to be pivotally connected to the inner cover (42) through hinges or straps.
The optical device (100) according to any of preceding claims, wherein the outer cover (44) is configured to be pivotally connected to a top edge (422) of the inner cover (42).
The optical device (100) according to any of claims 1 to 6, wherein the outer cover (44) is configured to be pivotally connected to a bottom edge (424) of the inner cover (42).
The optical device (100) according to claim 2, wherein the locking mechanism (60) comprises any of a press-fit mechanism or a snap-fit mechanism or hooks or glue tape.
A method of assembling at least one double cover assembly (40) on at least one support structure (30) of an optical device (100), the assembly process comprises the steps of:
- mounting a first light guide (20) on the at least one support structure (30) of the optical device (100), wherein a light entry portion (22) of the first light guide (20) is arranged facing a light source (10);

- mounting at least one double cover assembly (40) on said support structure (30), wherein an inner cover (42) of the at least one double cover assembly (40) is configured to be hingedly mounted on the at least one support structure (30) to cover the light entry portion (22) of the at least one light guide (20);

- mounting a second light guide (20') over the inner cover (42) of the at least one double cover assembly (40);

- rotating an outer cover (44) of the at least one double cover assembly (40) to cover the light entry portion (22') of the second light guide (20'); and

- securing the outer cover (44) with the inner cover (42) by a locking mechanism (60).