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The present invention relates to a lens unit for a vehicle lighting device. Further, the present invention relates to a vehicle lighting device, a vehicle comprising a vehicle lighting device and a method of manufacturing a lens unit.
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Lighting devices for vehicles (vehicle lighting devices) commonly have a complex structure. In addition to lens elements for light shaping, reflectors are also required to generate a desired light distribution. The components that determine the light distribution must also be matched to each other and positioned as precisely as possible. Since the installation space and the costs of such lighting devices should always be kept as low as possible, particularly in the context of an application in vehicles, the general aim is to reduce the complexity, the required installation space as well as the required effort for manufacturing.
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It is therefore the objective of the present invention to overcome at least one of the aforementioned disadvantages at least partially. In particular, it is the object of the invention to provide a lens unit for a vehicle lighting device, a vehicle lighting device, a vehicle and a method of manufacturing a lens unit, which allow for a compact and less complex design of a vehicle lighting device preferably without having to compromise on functionality, in particular with regard to achieve a desired light distribution.
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The aforementioned task is solved by a lens unit for a vehicle lighting device according to a first aspect of the present invention, by a vehicle lighting device according to a second aspect of the present invention, by a vehicle according to a third aspect of the present invention as well as by a method of manufacturing according to a fourth aspect of the present invention. Features and details which are described in connection with the lens unit also apply in connection with the vehicle lighting device and/or the vehicle and/or the method of manufacturing and vice versa, so that reference is or can always be made mutually with regard to the disclosure concerning the individual aspects of the invention.
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According to a first aspect, the present invention refers to a lens unit for a vehicle lighting device, comprising a light shaping element having a planar or substantially planar base portion, wherein in said base portion, at least one lens portion for shaping a light distribution is formed, said lens portion having a length extension along a longitudinal axis between first outer edges of the lens portion and a height extension along a height axis oriented perpendicular to said longitudinal axis between second outer edges of the lens portion, wherein from the first outer edges, the height extension of the lens portion at least partially tapers inwards along the longitudinal axis towards a minimum height extension.
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In other words, a lens unit for a vehicle lighting device is provided. The lens unit comprises at least one, in particular exactly one, light shaping element having a planar or substantially planar base portion. In said base portion, at least one lens portion is formed, for creating a desired light distribution. A single lens portion can be provided to generate a partial light distribution, which contributes accordingly to an overall light distribution of the lens unit.
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Said lens portion formed in the base portion has a length extension along a longitudinal axis between a first outer edges, preferably a first pair of outer edges. Further, the lens portion has a height extension along a height axis between second outer edges, preferably a second pair of outer edges, wherein the height axis is oriented perpendicular or essentially perpendicular to the length axis. Preferably, the first outer edges and the second outer edges form the circumference of the lens portion and/or mark the transition between the lens portion and the base portion. The height axis and the length axis may preferably be parallel or essentially parallel to the planar extension of the base portion.
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According to the invention, from the first outer edges, the height extension of the lens portion at least partially tapers inwards along the longitudinal axis towards a minimum height extension. Therefore, the lens portion is at least partially constricted with regard to its height extension along its longitudinal extension between the first outer edges. In particular, at least one lens portion has a butterfly-like shape.
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Due to the characteristic butterfly-like shape of the lens portion, light is be distributed more widely along the longitudinal axis. In particular, light distributions can be realized in this way that could previously only be achieved with the additional use of reflectors. By using a lens unit according to the invention, the additional use of reflectors can be dispensed, allowing for a simpler and overall space-saving design to be realized.
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With regard to the present invention, it may be provided that a plurality of lens portions are formed in the base portion. In particular, these lens portions may be identical or essentially identical. By means of multiple lens portions, larger light distributions can be created in connection with the use of multiple light sources. Preferably, at least two or at least four, in particular exactly four, lens portions may be formed. In case that four lens portions are provided, the lens portions may be arranged in such a way that the surface centers of the lens portions in relation to their longitudinal and vertical extension form corner points of a rectangle or square.
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It may be provided that a, preferably maximum, length extension and/or the, preferably, maximum height extension of at least one lens portion is in the range of 5 mm to 30 mm, in particular between 10 mm to 25 mm. Additionally or alternatively, it may be provided that the, preferably maximum, height extension of at least one lens portion is smaller than the, preferably maximum, height extension of said lens portion. For example, the, preferably maximum, height extension may be in the range of 70 % to 90 %, preferably 75 % to 85 % of the, preferably maximum, length extension.
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It may further be provided that at least one lens portion is formed mirror-symmetrically with respect to a reflection in a plane, oriented perpendicular to the longitudinal axis and/or height axis.
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With regard to the present invention, it may be provided that the minimum height extension of the lens portion is centered between the first outer edges along the longitudinal axis. This allows to achieve a symmetrical distribution of light in relation to the longitudinal axis.
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Further, it may be provided that at least one first outer edge of at least one lens portion, preferably both first outer edges, are curved inwards towards the minimum height extension of the lens portion respectively towards a centroid of the lens portion in the plane defined by the longitudinal axis and the height axis. This allows an improved light distribution to be achieved, particularly at the edges.
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Additionally or alternatively, it may further be provided that at least one lens portion is at least partially elevated relative to the base portion on a light entry side of the light shaping element. In other words, it can be provided that the lens portion protrudes from the base portion on the light entry side of the light shaping element. This allows an advantageous radiation behavior into the lens portion when it is used with a light source. Additionally or alternatively, at least one lens portion may be arranged flush with the base portion on a light exit side of the light shaping element.
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A light entry side of the light shaping element is to be understood as a side into which light is irradiated from a light source. A light exit side of the light shaping element is to be understood as a side from which the light that entered via the light entry side emerges. This refers to an intended use of the lens unit, preferably in a vehicle lighting device.
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With regard to the present invention, it may be advantageous if, preferably at least along the first outer edges, the elevation of the lens portion relative to the base portion at least partially increases from the second outer edges inwards along the height axis towards a maximum elevation. In particular, this may refer to each position along the longitudinal axis respectively length extension of the lens portion. This allows a broader distribution of light along the vertical axis. In this context, it may be beneficial if the maximum elevation of the lens portion is centered between the second outer edges. In particular, this may refer to each position along the longitudinal axis respectively length extension of the lens portion. This allows to achieve a symmetrical distribution of light in relation to the height axis. Preferably, the elevation may extend along a depth axis, wherein said depth axis is oriented perpendicular or essentially perpendicular to the height axis and the longitudinal axis.
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Additionally or alternatively, the elevation of the lens portion relative to the base portion may at least partially taper inwards along the longitudinal axis, wherein preferably a minimum elevation with regard to said taper is centered between the first outer edges. This has also shown to be beneficial for an improved light distribution.
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In particular, the second outer edges may be at least partially flush with the base portion on the light entry side. Additionally or alternatively, the first outer edges may be at least partially elevated relative to the base portion on the light entry side.
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It may further be provided that the lens unit further comprises a housing element, wherein said housing element encloses the light shaping element at least partially, preferably entirely, along an outer circumference of the light shaping element. Preferably, it may be provided that the housing element is made from an opaque or essentially opaque material, in particular from an opaque polymer and/or that the light shaping element is made from an at least partially translucent material, in particular from a translucent polymer. This allows to emit light only or essentially only through the light shaping element, whereby the generation of a sharp light distribution can be realized.
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It may be particularly advantageous to provide that the housing element and the light shaping element are configured as a monolithic unit, in particular as a two-component injection-molded part. This allows for a strong and reliable connection between the housing element and the light shaping element, as well as for a cost-effective and time-efficient production of the lens unit.
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Additionally or alternatively, it may be provided, that the light entry side of the light shaping element is at least partially, preferably entirely, grained. In other words it may be provided that the light shaping element, in particular at least one lens portion and/or the base portion, has a structured surface on the light entry side. This allows to spread the light more uniform as well as to reduce the effect of color aberration.
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According to a second aspect, the present invention refers to a vehicle lighting device comprising at least one lens unit according to the first aspect of the present invention. Thus, the same advantages arise in relation to the vehicle lighting device as already described in relation to the lens unit device.
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Advantageously, it can be provided that the vehicle lighting device further comprises at least one light source, wherein said light source is arranged relative to a lens portion of the light shaping element, such that the light emitted by the light source is emitted or essentially emitted into the lens portion, preferably on a light entry side of the light shaping element. Advantageously, the number of light sources can correspond to the number of lenses, with one light source preferably being provided for each lens portion.
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In particular, at least one light source may be provided as a light emitting diode (LED). Additionally or alternatively, at least one light source may be arranged on a printed circuit board (PCB). Hereby, a control of said light source and an energy supply of said light source can be realized in an easy and efficient way. Preferably, at least two light sources or all light sources may be provided on a single PCB. This results in a particularly simple structure of the vehicle lighting device.
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At least one light source may be aligned with a central axis of a lens portion. The central axis may preferably be oriented perpendicular to the height axis and length axis and intersect the center of the longitudinal extension and the center of the height extension of the lens portion. This results in an advantageous irradiation of the light source into the lens portion.
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According to a third aspect, the present invention refers to a vehicle comprising at least one vehicle lighting device according to the second aspect of the present invention. Thus, the same advantages arise in relation to the vehicle as already described in relation to the lens unit and/or the vehicle lighting device. In particular, the vehicle may comprise a plurality of, preferably identical or essentially identical, lighting devices.
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It may be provided that the vehicle lighting device is configured as a reverse maneuvering lamp or a working lamp of the vehicle. Using the lamp as a working lamp has proven to be particularly advantageous in the present case. Additionally or alternatively, the vehicle lighting device may be mounted on a vehicle body, preferably on an outer panel of the vehicle body. The vehicle can preferably be designed as a car. Alternatively, the vehicle can be designed as a commercial vehicle, in particular as a truck. Alternatively, the vehicle can be designed as an agricultural machine, in particular a tractor.
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According to a fourth aspect, the present invention refers to a method of manufacturing a lens unit, wherein said lens unit is a lens unit according to the first aspect of the present invention. The method comprises:
- 0 Forming the light shaping element in an injection molding process, in particular from an at least partially translucent polymer, in particular a, preferably synthetic, plastic.
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Thus, the same advantages arise in relation to the method for manufacturing a lens unit as already described in relation to the lens unit and/or the vehicle lighting device and/or the vehicle. Furthermore, manufacturing the lens unit as an injection-molded part is a particularly efficient and cost-effective way of producing it.
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The polymer used for forming the light shaping element may be completely or substantially completely transparent.
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With regard to the present invention, it may further be provided, that the lens unit further comprises a housing element, wherein said housing element encloses the light shaping element along an outer circumference of the light shaping element and wherein the method further comprises:
- 0 Forming the light shaping element and the housing element as a monolithic unit in a two-component injection-molding process, wherein preferably the housing element is made from an opaque or essentially opaque polymer.
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The manufacture of the lens unit in a 2-component injection molding process enables time-efficient and cost-effective production. Also, a reliable connection between the light shaping element and the housing element is provided. The two components may differ in at least additive, e.g., color pigments, and/or in the polymer used for the light shaping element and the housing element.
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The polymer used for the light shaping element and/or the housing element may preferably be a thermoplastic polymer, in particular Acrylonitrile Butadiene Styrene (ABS).
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With reference to the accompanying drawings, the present invention is explained in more detail below, wherein
- Figure 1 shows a schematic isometric view of a lens unit,
- Figure 2 shows a schematic front view of a lens unit,
- Figure 3 shows a schematic view of a lens portion,
- Figure 4 shows a sectional view of a lens unit,
- Figure 5 shows a sectional view of a lens unit,
- Figure 6 shows a schematic exploded view of a vehicle lighting device,
- Figure 7 shows a schematic exploded view of a vehicle lighting device,
- Figure 8 shows a schematic view of a vehicle and
- Figure 9 shows a schematic view of a method.
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In the figures, identical reference signs are used for the same technical features, even in different embodiments.
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Fig. 1 shows a schematic isometric view of a lens unit 10 for a vehicle lighting device 50 according to a first aspect of the invention.
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Fig. 2 shows a schematic front view of this lens unit 10.
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The lens unit 10 comprises a light shaping element 11 having a planar or substantially planar base portion 12, wherein in said base portion 12, at least one lens portion 13 for shaping a light distribution is formed.
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For a better overview, a schematic view of such a lens portion 13 is shown in fig. 3.
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It can be seen from fig. 3 that said lens portion 13 has a length extension along a longitudinal axis X between first outer edges 14 of the lens portion 13 and a height extension along a height axis Y between second outer edges 15 of the lens portion. The height axis Y is oriented perpendicular to the longitudinal axis X. It can further be seen from fig. 3 that from the first outer edges 14 of the lens portion 13, the height extension of the lens portion 13 at least partially tapers inwards along the longitudinal axis X towards a minimum height extension Hmin, whereas in the present case, the minimum height extension Hmin of the lens portion 13 is centered between the first outer edges 14 along the longitudinal axis X. Due to the characteristic butterfly-like shape of the lens portion 13, light is be distributed more widely along the longitudinal axis X, and light distributions can be realized in this way that could previously only be achieved with the additional use of reflectors.
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With regard to fig. 1 and 2, it can be seen that multiple identical or essentially identical lens portions 13 are formed in the base portion 12. From fig. 3, it can further be seen that said lens portions 13 are formed mirror-symmetrically with respect to a reflection in a plane oriented orthogonally to the longitudinal axis X (parallel to the height axis Y) and a plane oriented perpendicular to the height axis Y (parallel to the longitudinal axis X).
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Further, it can be seen from fig. 3 that the first outer edges 14 are curved inwards towards the minimum height extension of the lens portion. This allows an improved light distribution to be achieved, particularly at the edges.
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Fig. 4 shows a schematic sectional view of the lens unit shown in fig. 1 and 2, wherein the sectional plane S1 is shown in fig. 2.
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Fig. 5 shows a schematic sectional view of the lens unit shown in fig. 1 and 2, wherein the sectional plane S2 is also shown in fig. 2. It can be seen from fig. 1, 4 and 5 that the lens portions 13 are arranged flush with the base portion 12 on a light exit side 16 of the light shaping element 11 and that the lens portions 13 are at least partially elevated relative to the base portion 12 on a light entry side 17 of the light shaping element 11. The elevation extends along a depth axis Z, wherein said depth axis Z is oriented perpendicular or essentially perpendicular to the height axis Y and the longitudinal axis X.
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It can be seen from fig. 4 that the elevation of the lens portion 13 relative to the base portion 12 at least partially tapers inwards along the longitudinal axis X, wherein preferably a minimum elevation with regard to said taper is centered between the first outer edges 14.
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It can be seen from fig. 1 and 5 that the elevation of the lens portion 13 relative to the base portion 12 at least partially increases from the second outer edges 15 inwards along the height axis Y towards a maximum elevation Emax, wherein said maximum elevation Emax of the lens portion 13 is centered between the second outer edges 15.
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From fig. 1, 2, 4 and 5, it can further be seen that the lens unit 10 further comprises a housing element 18, wherein said housing element 18 encloses the light shaping element 11 entirely along an outer circumference of the light shaping element 11.
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In the present case, the housing element 18 is made from an opaque material, in particular from an opaque polymer and/or that the light shaping element 11 is made from an at least partially translucent material, in particular from a translucent polymer. The housing element 18 and the light shaping element 11 are configured as a monolithic unit, in particular as a two-component injection-molded part.
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Fig. 6 and 7 show schematic exploded views of a vehicle lighting device 50 according to a second aspect of the invention, wherein said vehicle lighting device 50 comprises at least one lens unit 10 according to the first aspect of the invention.
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Further, the vehicle lighting device 50 comprises at least one light source 51, wherein said light source 51 is arranged relative to a lens portion 13 of the light shaping element 11, such that light emitted by the light source 51 is emitted or essentially emitted into the lens portion 13 on a light entry side 17 of the light shaping element 11. In the present case, the light source 51 is proved as a LED which is arranged on a Printed circuit board (PCB) 52.
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Fig. 8 shows a schematic view of a vehicle 70 according to a third aspect of the present invention, the vehicle 70 comprising at least one vehicle lighting device 50 according to the second aspect of the invention.
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Fig. 9 further shows a method 100 of manufacturing a lens unit 10, wherein said lens unit 10 is a lens unit 10 according to the first aspect of the present invention. The method comprises:
- 0 Forming 110 the light shaping element 11 in an injection molding process, in particular from an at least partially translucent polymer.
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The preceding explanation of the embodiments describes the present invention exclusively by way of examples. Individual features of the embodiments can be freely combined with one another, provided this is technically feasible, without departing from the scope of the present invention.
List of reference signs
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- 10
- Lens unit
- 11
- Light shaping element
- 12
- Base portion
- 13
- Lens portion
- 14
- First outer edges
- 15
- Second outer edges
- 16
- Light exit side
- 17
- Light entry side
- 50
- Vehicle lighting device
- 51
- Light source
- 52
- Printed circuit board
- 70
- Vehicle
- 100
- Method
- 110
- Forming
- X
- Longitudinal axis
- Y
- Height axis
- Z
- Depth axis
- S1
- Sectional plane
- S2
- Sectional plane