The present application claims priority to and all the benefits of German Patent Application No. 10 2014 216 127.4, filed on Aug. 13, 2014, which is hereby expressly incorporated herein by reference in its entirety.
1. Field of the Invention
The present invention relates to a projection lens module for a motor vehicle headlamp having a central lens mount.
2. Description of the Related Art
A light module of this type is generally known in the related art and has a light source, a primary lens that bundles the light from the light source into an intermediate light distribution, a mirrored shutter delimiting the intermediate light distribution with a shutter edge, a projection lens that projects the delimited intermediate light distribution in a region in front of the light module, and a retaining structure that retains the light source with the primary lens, the mirrored shutter and the projection lens. The first retaining structure has a lens mount, which has an end at the light source side and an end at the projection lens side. The end at the projection lens side has a lens receiver, which is configured for accommodating the projection lens and retaining said lens by a form fit and/or force fit.
There are numerous types of projection lens modules for motor vehicle headlamps that are generally known in the related art. Classic poly-ellipsoid headlamp modules (PES modules), the name of which is derived from the shape of the reflectors used as the primary lens, normally have reflectors having light sources placed therein, as well as shutters and lens elements placed in the luminous flux of the light source. Modules with semiconductor light sources, in particular with light emitting diodes or laser diodes, which are in thermal contact with a heat sink that is attached thereto are also known. The shutters and lenses are also attached to this, normally massive, heat sink.
The projection lenses of the known light modules are attached to the lens mounts by springs, retaining rings, clamps, welding, injection molds etc. Provided that the known light modules have a heat sink and a lens mount, these do not contribute to the cooling.
With nearly all light modules, a mechanical color fringe adjustment is necessary. The undesired color fringe generated by a projection light module is the result of the different refractive powers of the projection lenses for different wavelengths. While the light beams of different wavelengths/colors refracted at different parts of the projection lens overlap in the bright region of the light distribution to form white light, a color fringe occurs at the light/dark border of the light distribution generated by the mirrored shutter. The intensity of the appearance of such a color fringe ultimately depends on component dimension tolerances and installation tolerances, which affect the spacing of the shutter edges from the projection lens and the shutter-side back focal length of the projection lens. The back focal length is to be understood to mean the distance from the outer surface vertex of the projection lens to the lens surface. The shutter edge is preferably disposed in the lens surface.
The spacing is adjusted during the installation of the light module for the mechanical color fringe adjustment, such that the color fringe appears to be as minimal as possible, i.e. having the lowest possible intensity. If no color fringe adjustment of this type is carried out, the color of the light at the light/dark border, depending on the magnitude of the tolerances, would constantly fluctuate on the street, which is distracting.
The invention is distinguished from the related art in that the lens mount is divided into a first component and a second component, wherein a separating surface lying between the two components cuts the lens mount, such that the mirrored shutter is clamped between the first component and second component, wherein the position of the mirrored shutter in relation to the two components of the lens mount is determined by inter-engaging form-fitting elements, and in that the mirrored shutter has spacers facing toward the projection lens, which are in contact with the projection lens.
Because the lens mount is divided into a first component and a second component by a separating surface, said separating surface cutting through the lens receiver, this initially simplifies the installation of the projection light module. The projection lens can simply be placed in the lens receiver of the one component, wherein the mount is completed by adding the second component. A flattening or otherwise shaping of an edge of a lens receiver, which reduces the diameter of an undivided lens receiver after the insertion of the projection lens, as is necessary with undivided lens receivers in order to retain the inserted projection lens, is not necessary.
Because the position of the mirrored shutter in relation to the two components of the lens mount is determined by inter-engaging form-fitting elements, a very simple installation of the mirrored shutter is obtained, in conjunction with a very high precision for the position of the shutter edge in relation to the lens mount. The clamping attachment likewise contributes, in conjunction with the form-fitting positioning, to a very low installation effort. Because the mirrored shutter has spacers facing toward the projection lens, which are in contact with the projection lens, a very high precision for the determination of the spacing between the shutter edge and the light entry surface of the projection lens is obtained, in conjunction with a very low installation effort.
As a result, the intensity of a color fringe is then dominated by the component manufacturing tolerances. The installation tolerances are negligible in comparison. It is then no longer necessary to adjust the color fringe when the remaining imprecision of the specified spacing is no greater than ±0.2 mm, which can be obtained with a typical manufacturing precision of the parts.
The possible elimination of the color fringe adjustment for low beam light, without sacrificing quality, reduces the manufacturing effort and the manufacturing costs, which is a substantial development objective. The fact that, with standard lens edge geometries, an attachment of the lens without additional parts can occur, likewise contributes to lower costs. Furthermore, the invention makes it possible to eliminate a heat sink, or at least to use a smaller heat sink than that used in the prior art. On the whole, a simplified production is obtained, in conjunction with lower tolerances and a reduction in the structural space, weight and costs. The object of the invention can thus be seen as that of providing a projection light module having these advantages, and which can be, in particular, manufactured in a very inexpensive manner, having acceptable lighting properties.
One embodiment is distinguished in that the separating surface cuts through the end of the lens mount at the light source side and the end of the lens mount at the projection lens side.
The separating surface may also run where the projection lens has its greatest diameter, and thus runs such that the projection of the separating surface is a straight line on the main plane of the projection lens.
In another embodiment the separating surface may be a flat separating surface. With an intended use of the light module in a motor vehicle headlamp in a motor vehicle, on a level driving surface, the separating surface preferably lies parallel to the horizon.
Another embodiment is distinguished in that the first component has a first flange having form-fitting elements and second flange having form-fitting elements in its separating surface, wherein the form-fitting elements of the second flange are dimensioned and disposed as a mirror image of the form-fitting elements of the first flange.
The mirrored shutter may also have a shutter section with a shutter edge and two attachment sections, as well as two spacers, and is rigid, wherein the attachment sections have a shape adapted to the flanges, and are disposed on the mirrored shutter such that, in each case, an attachment section rests against one of the flanges, and wherein the attachment sections extend toward the lens receiver, over the flanges, and thus form spacers that are long enough that they are in contact with the projection lens placed in the lens receiver. The mirrored shutter has local matting in one design. In a further design the mirrored shutter is disposed horizontally, such that its shutter edge is projected by the projection lens as a light/dark border of a low beam light that conforms to regulations.
In one embodiment the spacers may be long enough that they are in contact with the projection lens with a slight tension.
Another embodiment is distinguished in that the second component has two flanges with form-fitting elements, which are dimensioned and disposed as a minor image of the flanges and form-fitting elements of the first component.
In yet another embodiment, the second component may have a base structure on its end lying opposite the end at the lens side, for attaching a printed circuit board having semiconductor light sources and primary lenses. The base structure may also be a part of the single-piece second component. The base structure may have a free end, which is preferably designed such that it can be fixedly connected to the light source side end of the first component by screws, rivets, swaging or a material bonding connection technology.
In one embodiment the second component is at least partially matte on its inner surface facing the mirrored shutter. The first component can also have an at least partially matte inner surface facing the shutter. In addition, the second component, and preferably also the first component, may each be composed of a material having good thermal conductivity, in particular a metal.
The lens mount may have second retaining structures, which are configured for retaining the light module in the headlamp. The second retaining structures may have spherical heads, with which the entire projection light module can be pivoted about an imaginary pivot axis running through both spherical heads.
In still another embodiment, the additional light sources may be disposed in the region beneath the level of the mirrored shutter. Such light sources can be used to supplement the low beam light distribution generated by the light sources disposed above the mirrored shutter, to form a high beam light distribution. It is to be understood that the features specified above, and to be explained below, can be used not only in the respective described combinations, but also in other combinations or in and of themselves, without abandoning the scope of the present invention.
Other advantages of the invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
Identical reference symbols indicate identical elements in the various figures thereby, or at least elements having comparable functions.
The lens receiver has channel-shaped receiving elements 25, which are configured, by their dimensions and arrangement, to encompass projections 27 protruding from an edge of the projection lens 16 in the manner of a collar.
In another exemplary embodiment, the projection lens has recesses on its edge, which are configured, by their dimensions and arrangement, to receive projections, protruding from the edge of the lens receiver and pointed toward the interior of the projection lens, in a precise fit.
The lens mount 20 is divided, between its two ends, into a first component 26 and a second component 28. The division runs such that a separating surface lying between its two components 24 and 26 cuts the light source side end 22 and the projection lens side end 24. The separating surface preferably runs through the projection lens side end 24 there where the projection lens 16 has its greatest diameter, and the separating surface runs beyond this, such that its projection on the main plane of the projection lens 16 is a straight line. The important thing is that the separating surface cuts the lens receiver such that the projection lens 16 can be accommodated in the divided lens receiver without any plastic deformation of the components of the lens mount 20. The separating surface must thus intersect the projection lens side end 24 having the lens receiver. It is not, however, absolutely necessary that the separating surface also intersect the light source side end 22 of the lens mount 20. The separating surface can also have one or more angles, run in numerous planes, and/or have one or more steps functioning as form-fitting elements.
This applies analogously to a second flange connection, which lies opposite the first flange connection described so far, in the separating surface, and which, in particular, has the second attachment element 32.2. The second flange connection is preferably, but not necessarily, designed as a minor image of the first flange connection.
By means of these features, the mirrored shutter 18 is positioned with a positioning imprecision, dominated by the manufacturing tolerances of the flanges, bores and alignment pins, on the first component 26.
The attachment sections 18.2, 18.3 protrude toward the lens receiver, beyond the flanges 26.1, 26.2. Those parts of the attachment sections 18.2, 18.3 that no longer server to attach the mirrored shutter 18 form spacers 18.4, 18.5, which improve the positioning precision of the projection lens 16 that will later be placed in the lens receiver.
The spacers 18.4, 18.5 of the mirrored shutter 18 are long enough that they are in contact with the projection lens 16 placed in the lens receiver. The spacers are preferably long enough that they are in contact with the projection lens 16 with a slight tension. Potential play that may be present under certain circumstances, without such spacers, or potential positioning imprecision of the projection lens in the lens receiver without such spacers, is limited by the contact. As a result, the potentially still remaining imprecision, even in the case of direct contact, of the variables that influence the color fringe (spacing of the projection lens to the mirrored shutter, back focal length of the projection lens) is dominated by the manufacturing imprecisions, and is only a result of the installation to a subordinate extent.
Reference is again made to
The second component 28 has two flanges 28.1, 28.2 having form-fitting elements, which are dimensioned and arranged as minor images of the flanges 26.1, 26.2 and form-fitting elements of the first component 26. When the mirrored shutter 18 is joined to the first component 26, the attachment elements 32.1, 32.2 and the second half-shell shaped component 28, structural components are formed, that are stacked on top of one anther and connected by form-fitting elements that engage with one another.
In the design depicted therein, the second component 28 has a base structure 29 on its end 22 lying opposite the lens side end 24, for attaching a printed circuit board having semiconductor light sources and primary lenses. The base structure 29 is a part of the single-piece second component 28 here. The second component 28, and preferably also the first component, are preferably each made of a material having good thermal conductivity, in particular a metal. A part of this type can be inexpensively manufactured by shaping a stamped sheet metal part, thus contributing to keeping the manufacturing costs as low as possible.
The semiconductor light sources are preferably disposed on a printed circuit board, in thermal contact with the base structure. The base structure has a free end 31, which is preferably designed such that it can be fixedly connected to the light source side end of the first component by screws, rivets, swaging, or a material bonding connection technology. A very high rigidity and mechanical stability of the lens mount 20 serving as the central, first retaining structure 17 is obtained by this connection. It is to be understood that the base structure can also be a component of the first half-shell, or the first component 26 of the lens mount. In one design, the light source assembly, which has, in addition to the light sources, at least one printed circuit board, can be designed such that it is replaceable. When numerous light source assemblies are used, for a low beam light distribution and a supplementary high beam light distribution, for example, preferably at least one of the two assemblies is designed such that it can be replaced.
A further major advantage of the use of a good thermal conductor such as metal as the material for the lens mount 20 is that the lens mount 20 itself, with its two half-shells 26, 28, can be used as a heat sink, because it accumulates heat from the chips of the semiconductor light sources through the contact with the printed circuit board, distributes the heat well, and can discharge the heat into the surrounding air through its large surface area. The service life of semiconductor light sources is substantially determined by their prevailing temperature during operation. As a result of the manner of construction presented in this application, by use of half-shell shaped components of the lens mount, which are preferably made of sheet metal, the lens mount 20 can either directly accommodate the printed circuit board with the semiconductor light sources, or can simply be connected, in a thermally conductive manner, to a separate heat sink. The lens mount 20 thus forms a heat sink, and in any case, contributes to the cooling thereof. This is accompanied with the advantage that the light module 10 either does not require a separate heat sink, or if such a heat sink is necessary, then it can be smaller, lighter and thus less expensive than with the prior art.
Reference shall be made below to
The spacers for the mirrored shutter 18 are dimensioned such that their length is sufficient for pushing the lens 18, with a slight tension, against the wall of the channel, such that the position of the projection lens, in the direction of its optical axis with respect to the shutter edge of the mirrored shutter 18, is determined by the spacing between the front edge of the spacer 18.4, 18.5 in contact with the projection lens and the bores 30 and the alignment pins 34, which spacing is only dominated by the manufacturing imprecisions and is substantially independent of installation imprecisions.
After joining the first component 26, the second component 28, the attachment elements 32.1, 32.2, the mirrored shutter 28, and the projection lens 19, in which the projection lens 16 and the mirrored shutter 18 are placed in a form-fitting manner between the half-shells, the respective components 28, 28 of the lens mount 20, the components are fixedly connected to one another. The fixed connection preferably occurs by riveting, swaging, in particular hot swaging, or screwing the two components 26, 28, or by a material bonding connection process, such as adhesion. The alignment pins can serve as attachment elements thereby, as rivets or as threaded studs, for example.
The light source 12 is preferably composed of an assembly of semiconductor light sources, which are attached, together with associated primary lenses 14 and a printed circuit board 15, to one of the two components. With the intended use of the light module, the light source 12 is located above the mirrored shutter. As already mentioned, one (or more) supplementary light source(s) can also be located beneath the mirrored shutter in an intended use thereof.
The spherical heads represent a design for second retaining structures, which are configured for retaining the light module in the headlamp. The spherical heads are preferably attached to the projections 33 or are a material bonded component of the projections 3.
The invention has been described in an illustrative manner. It is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the invention may be practiced other than as specifically described.
Number | Date | Country | Kind |
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10 2014 216 127.4 | Aug 2014 | DE | national |