The present invention relates to an optical waveguide and its use in a lighting device equipping a motor vehicle, in particular an automotive vehicle.
The use of optical waveguides is becoming increasingly common in the field of automotive vehicle lighting and signalling. In fact, these have the advantage of being able to adopt highly varied geometric forms and to create an illuminating surface even in less accessible regions of the lighting and/or signalling device. This is particularly beneficial in the present context, where the designers of motor vehicles are seeking to impart a unique signature to their vehicles, in particular by proposing complex shapes for the headlights, which are also referred to as headlamps.
The expression “optical waveguide” is used in the present application to denote a transparent or translucent component, in the interior of which light beams are propagated in a controlled manner from one of the extremities of the waveguide, referred to as the input face, to at least one output face. The propagation of the light in a controlled manner is generally performed by successive total reflections on various internal reflection faces to the optical waveguide.
In practical terms, at least one light source is disposed close to the input face, for example a light-emitting diode. The light beams emitted by said source will be propagated in the optical waveguide towards the face opposite the input face, referred to as the end face, by means of parallel internal reflection faces situated between the input face and the end face.
In certain optical waveguides, the light beams may be directed in the direction of a different secondary output face from the end face, in such a way that an observer then has the impression that said secondary output face is illuminated directly by a light source. According to certain modes of implementation, for example as described in application FR 2 891 891, said output face is in particular one of the internal reflection faces. For this purpose, the shape of a first internal reflection face is modified so that it is no longer parallel to the second internal reflection face, such that the incident beams, as they meet the first face in the area of this interruption, are directed onto said second internal reflection face with an angle of incidence such that, instead of being reflected on this second internal reflection face, the beams pass through it and exit from the waveguide. These modifications to the shape of the first internal reflection face may be obtained by the provision of prisms, as described in application FR 2 891 891. It has been observed that such optical waveguides including prisms make it possible to obtain the emission of an anisotropic light oriented in the axis of the vehicle. Although such a design approach is advantageous in that it permits compliance with photometric standards, the designers of motor vehicles also wish to propose visually pleasing lighting and/or signalling devices, in particular by a uniform illuminated appearance regardless of the position in which an observer views the vehicle, both in the longitudinal axis of the vehicle and from the side.
Also familiar, furthermore, is the patent application published under number WO 00/50807, which discloses illuminated panels including an optical waveguide in the form of a panel and which includes on one of its faces a distribution of patterns (indented or raised) that are integral with said face. The different embodiments of the patterns proposed in this document ensure an anisotropic illumination, and certain of them ensure an illumination which is also uniform. However, if the described solutions are adapted in particular for the production of phototherapy appliances or to provide backlighting for a display screen, they would not then be suitable for the production of curved optical waveguides for automobile lighting and/or signalling devices, which guides are in addition inclined in relation to the frontal plane perpendicular to the optical axis of the device, that is to say to a vertical plane, the optical axis being substantially parallel to the horizontal, and which moreover would meet the mandatory photometric standards.
In this context, the invention proposes an alternative to the lighting devices for motor vehicles, in which an optical waveguide permits illumination which is both uniform and anisotropic, and which makes it possible to design devices that are curved and are also inclined in relation to the frontal plane in the optical axis of said devices. This alternative should also be easy to accomplish and inexpensive.
The invention proposes an optical waveguide for the propagation of a light beam designed to travel by successive total reflections off the faces of said guide to an output face where the beam is refracted, in which one of the faces forms, facing towards the output face, a support face for a pattern extending across the main direction of the beam to divert same towards the output face. According to a characterizing feature of the invention, the pattern is a bifunctional reflective pattern that is integral with the support face and combines the means for the implementation of a focussed reflection of the beam towards the output face and the means for the implementation of a multidirectional reflection of this same beam.
Two distinct effects are thus combined in a pattern that is integral with one of the faces of the optical waveguide. Efficient illumination is permitted in the axis of the vehicle in order to meet the photometric standards, by concentrating the beam on a given point, and diffusion of the light in all directions is permitted at the same time in order to ensure that the general appearance of the illumination is coherent and uniform, regardless of whether the vehicle is being observed from the front or from the side.
The use of the expression “integral with” in the present application is intended to denote that the patterns are produced directly in the guide, in the mass, or that they emerge therefrom, as opposed to patterns that are applied to said guide, for example by means of an adhesive film covered with said patterns.
In one particularly advantageous mode of implementation of the invention, the bifunctional reflective pattern has three successive portions including end portions formed by cone portions, between which there is interposed an intermediate portion having plane or curved faces. The double reflection function is accomplished by connecting together two geometries having different optical benefits. The intermediate portion permits the light beam to be concentrated on a precise zone of the output face, whereas the cone portions assure the multidirectional reflection.
According to a characterizing feature of a first mode of implementation of the invention, the intermediate portion includes two facets, both plane and non-parallel, which meet at a top edge, in such a way as to have a triangular section. Said facets are symmetrical to one another in relation to the plane perpendicular to the support face for the patterns and passing through the top edge. This symmetry is particularly beneficial for the method of manufacture of the invention. According to a characterizing feature of a second embodiment of the invention, the intermediate portion includes two dissymmetrical curved facets which meet at a curved top edge. According to a characterizing feature of the invention, said facets are inclined in relation to the horizontal plane in two directions. On the one hand they are inclined by rotation through a defined angle about an axis parallel to the support face, and, on the other hand they are inclined by rotation through a defined angle about an axis perpendicular to said support face. According to the calculated angles of inclination, the top edge of the intermediate portion is then not parallel to the support face for the patterns. The facets thus have a slope adapted to reflect the beams to enable them to meet the output face, on the one hand with the desired vertical component, and on the other hand with the desired transverse component, in order to be refracted and directed at the outlet from the optical waveguide in the desired optical direction. It should be noted that the orientation of the top edge will be particularly considered for the method of manufacture of the invention.
In one particular arrangement of the invention, the support face includes a plurality of bifunctional patterns placed side by side forming a line in a transverse direction to the main direction of travel of the light beam in the guide. In the event that the support face were to include several lines of patterns, it is of benefit, furthermore, for the patterns as a whole to be disposed in a staggered fashion.
It is also possible to propose that the support face in addition includes patterns having shapes that are different from those of the previously mentioned bifunctional patterns, and, for example, patterns adopting the form of cones, of which the axis is normal to the support face for the patterns.
According to the characterizing features of a preferred mode of implementation of the invention, the optical waveguide is formed by a sheet of transparent material which has the form of a parallelepiped including in particular two main faces which are substantially parallel to each other, and of which one forms said output face and the other said support face, as well as a proximal edge adapted to receive a light source, of the light-emitting diodes type, which transmits light into the thickness of the optical waveguide, and a distal edge, which constitutes the extremity opposite the proximal edge and which has a coating or a specific geometric profile permitting the light beam to be directed in the optical waveguide.
The presence of this coating has a significant impact on the illuminated appearance of the waveguide: it makes it possible on the one hand to recover the light, which has a tendency to escape from the waveguide via the distal edge, and it also makes it possible to direct the light beams with a high angle of incidence, which will encourage the exit of the light beam in a desired direction, as described below.
The invention also relates to a lighting device for a motor vehicle, including a cover lens and a light source, as well as an optical waveguide for the propagation of a light beam. An output face of the optical waveguide, being smooth and continuous, is disposed facing towards the cover lens, while a parallel face includes bifunctional reflective patterns forming an interruption in the regular profile of the support face, said patterns having three portions, including end portions, formed by cone portions, between which there is interposed an intermediate portion having plane faces.
Said lighting device for a motor vehicle may be:
a device for illuminating the road, which is also referred to as an illuminating device (the use of the expressions “illuminating device”, in the absence of indications to the contrary, denotes a device for illuminating the road); for example a front headlight of a motor vehicle, which is also referred to as a headlamp,
a device for signalling, for example a direction indicator, or a rear position lamp, or even a daytime signalling lamp, which is also referred to as a DRL (for “Day Running Light”),
an interior lighting device, namely a device in the interior of the passenger compartment of the vehicle, for the purpose of illuminating the latter or to provide background illumination.
According to a characterizing feature of the invention, the cover lens has a curvature in the transverse direction which the optical waveguide follows. The support face of the waveguide has at least one line of bifunctional patterns, and the inclination of the intermediate portion of the patterns varies from one pattern to the other along one and the same line.
Finally, a description is given of a method of manufacturing an optical waveguide for the propagation of a light beam including bifunctional reflective patterns that are integral with one of the faces of the optical waveguide. As a first step, a flat plate is deformed in order to obtain reliefs corresponding to the shapes of the bifunctional patterns and to their desired arrangement in lines and in a staggered fashion. This deformation is performed by means of a single tool, in the form of a cone. The tool is pressed into the plate in order to form a conical impression, and the tool is then displaced according to a director in a given direction, the director being curved or straight. The resulting plate is then placed in the mold, for example by orienting the reliefs towards the interior of the mold, and the material is injected. The guide is then formed by this injected material. The complex patterns that are integral with the support face are thus realized advantageously in this way with little tooling. The same tooling may be used to produce patterns on the different slopes, by the calculation in advance of the director which the tool must follow in the form of a cone. This process may be used advantageously in order to form a guide according to the present invention.
The invention will now be described more fully within the context of preferred characterizing features and their advantages, with reference to
and
The expression “longitudinal direction” L is used below to denote the direction in the direction of driving of the automotive vehicle, and “transverse direction” T to denote a direction that is horizontal and perpendicular to said longitudinal direction. The vertical direction V designates the direction perpendicular to the two preceding directions, which also define a horizontal plane. The trihedron L,V,T is placed on certain figures for ease of reading.
A lighting and signaling device is represented in
The light source emits a light beam in the interior of the headlight and an optical waveguide 6 is disposed in the interior of said headlight in order to receive and propagate said light beam to an output face of the guide 8 situated facing towards the cover lens. The optical waveguide is configured with the aim of following the shape of said lens.
The light source may consist of a series of light-emitting diodes which transmit light into the thickness of the optical waveguide, where it is trapped thanks to the total internal reflection between the faces of the sheet constituting the optical waveguide.
The sheet has the form of a parallelepiped, which is substantially plane or curved. The faces of said sheet each form a diopter separating the air from the interior of the sheet made from a transparent material. It is possible to distinguish in particular two main faces 10 and 12, which are substantially parallel to each other, as well as a proximal edge 14, against which the light source is disposed, and a distal edge 16, which constitutes the edge opposite the proximal edge, and which lacks a light source in this case. A second light source on the distal edge could be proposed as a variant.
The proximal edge has cavities 18, each being adapted to receive a diode head of the light source, so as to exploit to a maximum the luminous flux emitted by the diodes. It will be appreciated that the receiving cavities may adopt different forms and a different number according to the modes of implementation. A plurality of these cavities may be proposed, each being intended to house a diode, or only a single continuous cavity, for example having the form of a portion of a cylinder, intended to accommodate several diodes in alignment. The respective dimensions and the forms of the cavities and the diode heads are preferably complementary, with sufficient clearance for the diodes to be capable of being housed easily in the cavities.
The light beams emitted from the light source disposed on the proximal edge move towards the distal edge. The latter has a coating or a specific geometric profile permitting the light beams 20 to be directed into the optical waveguide in the direction of the proximal edge, as can be seen in
Each light beam 20 arrives at a face of the transparent sheet at an angle α in relation to the normal to the point of incidence N. When the angle α is smaller than the defined threshold angle β, the light beam is refracted outside the optical waveguide. And when the angle α is greater than this defined threshold angle β, the light beam is reflected totally in the interior of the optical waveguide, and as a result it is propagated in the optical waveguide by successive total reflections off the faces of the sheet.
According to the invention, the optical waveguide is configured so that the light beam, as it exits via the output face 8, produces horizontal lines 7 on the cover lens, as can be seen in
The output face is formed by one of the main faces of the sheet. Said first face is disposed facing towards the cover lens of the headlight. It is smooth and continuous. The second face extends parallel to the first face, and it differs from the latter by being a support face 23 for reflective elements forming an interruption in its regular profile. The reflective elements are patterns, projecting from the second face, which act as a secondary optical source by constituting internal reflection faces other than those of the waveguide, onto which an incident light beam is capable of being reflected.
The incident light beams which meet the patterns formed in this way are directed towards the first face, which they reach at an angle α smaller than the threshold angle β. Said beams are thus refracted via the output face formed by the first face, and they are directed towards the cover lens of the headlight in the plane of incidence defined by the incident beam and by the normal to the point of incidence.
The patterns formed on the optical waveguide include at least one bifunctional reflective pattern 24, which has conical end portions 26 between which there is interposed an intermediate portion 28 having plane faces.
In a first mode of implementation, as illustrated in
The dimension of the facets is determined according to the dimension of the optical waveguide and the calibration of the light beam circulating within the guide. By way of example, they have a depth of approximately 0.25 mm and a width of approximately 1 mm. Said patterns advantageously have the same dimensions, in particular with a view to the simplification of the manufacturing tools.
The facets of the intermediate portion have a slope calculated to permit the incident beams to be reflected in a preferred direction. Said slope is visible in particular in
The facets are inclined on the one hand in relation to the horizontal plane by an angle defined by calculation about an axis parallel to the support face for the patterns.
Said inclination, which is visible in
On the other hand, the facets are likewise inclined in relation to the horizontal plane by rotation about an axis normal to the support face for the patterns.
The angle of rotation is determined by calculation in order that the inclination in this plane, as depicted in
It will thus be appreciated that any patterns that are disposed on the first support face when the latter is only frontal, that is to say perpendicular to the direction of driving of the vehicle, do not require to be inclined in relation to the horizontal plane and about an axis normal to the support face for the patterns, the plane of incidence in which the beams are reflected and refracted naturally being parallel to the optical axis.
The conical portions are disposed to either side of the intermediate portion so as to reflect the beams of light in all directions and to assure a radiation function which the intermediate portion does not perform. Said conical portions are formed by cone portions, of which the base is combined with the support face of the waveguide, and of which the top is formed by the corresponding extremity of the edge of the intermediate portion. The two portions of a cone that are disposed to either side of the intermediate portion have the same angle at the top θ (as illustrated in
In a second mode of implementation, illustrated in
In these two previously described modes of implementation, as illustrated in
When several lines of bifunctional patterns are proposed, an arrangement of said lines can be provided advantageously on the support face, such that the patterns are disposed in a staggered fashion. It will thus be appreciated that a shallow beam may pass between two patterns on one and the same line without being reflected before coming into contact with a pattern on the following line.
As illustrated in
The method of manufacturing the optical waveguide, as described above, with patterns that are integral with one of the faces of the optical waveguide is described below. The patterns may be obtained directly during the molding of the optical waveguide by providing the mold with appropriate reliefs, the expression relief being used here in a generic sense and serving to designate a raised or indented formation.
As a first step, a flat plate is machined so that it includes, on completion of the machining process, reliefs corresponding to the shapes of the bifunctional patterns and to their arrangement in a line and in a staggered fashion. The machining is carried out advantageously with a single tool, in the form of a cone. The plate is deformed by insertion of the tool in such a way as to form a first conical portion, and the tool is then displaced according to a director in the same direction as that of the edge of the intermediate portion of the pattern. If the top is intended to be parallel to the support face for the patterns, the tool is displaced laterally without variation in the depth, whereas, if it is intended that the pattern has a sloping top, the depth of insertion of the tool is varied during its lateral displacement. Similarly, if it is wished to obtain patterns according to the first embodiment, with an intermediate portion having plane faces, the tool is displaced laterally in a straight line, whereas it is displaced laterally according to a curved director if it is wished to obtain patterns according to the second embodiment, with an intermediate portion having curved faces.
The lateral displacement of the tool generates the intermediate portion, with two facets being produced to either side of the plane perpendicular to the plate. When the tool is stopped, its conical form instantly generates the second conical portion.
The plate is then placed in the mold while orienting the reliefs towards the interior of the mold, and the material is injected. In this way, the patterns produced in negative format on the plate will then be produced in positive format, that is to say in embossed format, on the injected component. An angle at the top of the intermediate portion that is sufficiently open for the demolding operation will have been arrived at by calculation.
The above description explains clearly how the invention permits the objectives that it has set for itself to be achieved and, in particular, makes it possible to propose a lighting device for a motor vehicle that is particularly effective. By connecting together two geometries having different optical benefits, that is to say by combining the prismatic and conical forms on one and the same pattern, efficient illumination is permitted in the axis of the vehicle in order to meet the photometric standards, by calculating the inclination of the prismatic surfaces in order to direct the light in the desired direction against the opposite face of the waveguide so that it is able, after refraction, to exit from the headlight in the axis of the vehicle, and along parallel lines that are spaced apart by a few millimeters. At the same time, diffusion of the light in all directions is permitted when the beam meets the conical zone, such that the general appearance is coherent and homogeneous, regardless of whether the vehicle is being observed from the front or from the side.
It is also possible to apply the optical waveguide according to the invention in a particular embodiment of a lighting device for a motor vehicle, although this is not represented here. The headlight has a symmetrical form in relation to a central axis, on which the light source is disposed, and the distal edge of each half headlight is disposed facing towards the other distal edge, by having each of the cavities for receiving a common light source disposed between the two distal edges. If this arrangement is clearly of benefit for the optimization of the light sources, it is beneficial in the context of the invention in that lines of light can be produced to either side of the row of light-emitting diodes forming the light source by reducing by two the number of calculations necessary for the shape and the orientation of the patterns.
In a variant that is not represented here, reflective elements are added to the support face for the patterns of the optical waveguide, which adopt the form of simple cones, of which the axis is normal to said support face. The diffusion of the light in all directions is increased in this way. Said cones may be disposed in a line parallel to the line of the bifunctional patterns described above, for example alternately, or they may be positioned between two successive bifunctional patterns on one and the same line. Depending on whether it is wished to place the emphasis on perfect photometry, or on a strong visual signature that is clearly visible on the sides, a more or less simple cone will be available between the bifunctional reflective patterns.
Number | Date | Country | Kind |
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1354570 | May 2013 | FR | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2014/060479 | 5/21/2014 | WO | 00 |