Automobile lighting device and method for manufacturing automobile lighting device

Abstract

The present invention relates to an automotive lighting device and a method for manufacturing the automotive lighting device. The lighting device (1) comprises a supporting element (2, 2'), the supporting element comprising a first part (3) and a second part (5). The first part (3) comprises a first part (4) of a channel structure, and the second part (5) comprises a second part (6) of the channel structure. The first part (3) and the second part (5) of the supporting element (2, 2') are joined by a foldable elongated area (7). When the foldable elongated area (7) is folded to form a closed channel structure, the first part (4) and the second part (6) of the channel structure cooperate. The channel structure comprises at least one inlet (11) and at least one outlet (12, 13). A method for manufacturing the automotive lighting device is also provided.

Description

Technical Field

[0001] The invention belongs to the field of headlights for motor vehicles and more particularly to the design of headlights for avoiding fogging in the outer glass. Background Art

[0002] Current headlights have to meet different requirements, which sometimes conflict with the design approaches. One example of this is related to the defogging problem.

[0003] When water vapor condenses on the inner surface of the glass, it causes fogging. The droplets are unsightly and affect the performance of the light, so great efforts have been made to solve this problem. However, in order to design modern and efficient lighting fixtures, lighting fixtures are becoming smaller and smaller, and walls of opaque material must surround the light source to avoid light leakage. But the opaque wall is an obstacle to the free path of dry air to reach the glass surface and avoid condensation.

[0004] Therefore, the better the solution is to avoid light leakage, the worse it is to avoid condensation on the glass, because the opaque walls form a tortuous demisting air path, which makes the flow rate very low and therefore the demisting speed very slow.

[0005] Furthermore, due to current designs, fogging can occur at various locations of the automotive lighting fixture, thus increasing the need to include several channels to bring air to these locations and resolve the issue.

[0006] A solution to this problem is therefore sought. Summary of the invention

[0007] The present invention provides a solution to improve the defogging performance by providing a vehicle lighting device according to claim 1 and a method for manufacturing a vehicle lighting device according to claim 11. Preferred embodiments of the invention are defined in the dependent claims.

[0008] Unless otherwise defined, all terms (including technical and scientific terms) used herein should be interpreted according to the conventions of the art. It will be further understood that, unless explicitly defined herein, terms of common usage should also be interpreted as conventional terms in the relevant art, rather than being interpreted in an idealized or overly formal sense.

[0009] In this text, the term “comprise” and its derivatives (such as “comprising”, etc.) should not be understood in an exclusive manner, that is, these terms should not be interpreted as excluding the possibility that the described and defined content may include other elements, steps, etc.

[0010] In a first aspect of the invention, the present invention provides an automotive lighting device, comprising a supporting element, the supporting element comprising:

[0011] a first portion comprising a first portion of a channel structure; and

[0012] a second portion, the second portion comprising a second portion of the channel structure,

[0013] in,

[0014] The first and second portions of the support element are joined by a foldable elongated region;

[0015] The first portion and the second portion of the channel structure cooperate when the foldable elongated region is folded to form a closed channel structure;

[0016] The channel structure includes at least one inlet and at least one outlet.

[0017] The automotive lighting device utilizes existing components to provide a closed channel structure that will allow air to reach different locations of the automotive lighting device, thus saving space within the interior of the lighting device.

[0018] Furthermore, the device can be produced in one piece by injection, since the closed duct is divided into two parts, so that the resulting duct can be demoulded, since the closed duct is not demouldable.

[0019] In some embodiments, the channel structure includes two or more outlets. This embodiment solves the problem of defogging two different locations without adding several channels to the automotive lighting device.

[0020] In some embodiments, the automotive lighting device may include an outer lens, and at least one outlet is arranged to provide ventilation to the outer lens. This enables defogging of the lens. If the channel structure includes several outlets, the several outlets may be arranged to provide ventilation to different positions of the outer lens. This enables improved defogging when the lens is highly curved.

[0021] In some embodiments, the support element is arranged in the lighting device as an "eyebow" so that one or more outlets enable ventilation of the outer lens. This will improve defogging.

[0022] For example, in the present invention, the closed channel structure may include several outlets, which are arranged along the closed channel structure and toward the outer lens. This enables uniform ventilation along the outer lens.

[0023] In some embodiments, the first portion of the channel structure comprises a groove, the groove comprising a first end and a second end. The first end comprises an inlet, and the second end communicates with the rest of the channel structure. The second portion of the channel structure comprises an oblique segment extending from the second portion and arranged such that when the foldable elongated region is folded, the oblique segment closes the groove to form a duct from the inlet to the second end, the duct forming an entry portion of the closed channel structure.

[0024] The second part of the channel structure comprises a protrusion. The oblique section may serve as the surface of the protrusion. The protrusion is arranged to fit into the groove in a manner spaced between the oblique section and the bottom of the groove so as to form a duct. This achieves an improved closure, thus limiting the risk of air leakage in the inlet part, which improves the efficiency of the air circulation towards the outlet or outlets, in particular when a fan is used at the inlet.

[0025] In some embodiments, the automotive lighting device further includes a venting element positioned in fluid communication with the inlet of the channel structure.

[0026] The ventilation element provides air from outside the vehicle lighting device to improve the demisting performance of the channel structure.

[0027] In some embodiments, the automotive lighting device further comprises a fan element arranged to move air into the inlet of the channel structure.

[0028] The fan element is advantageous because it improves the air circulation in the channel structure and thus improves the demisting effect.

[0029] In some embodiments, the support element is made of plastic injection.

[0030] Plastic injection is a simple way to obtain this part. The feasibility is ensured by dividing the closed channel into open parts.

[0031] In some embodiments, the support element is a decorative frame. In other embodiments, the support element is a housing or a harness cover.

[0032] These elements are already present in automotive lighting devices, so using them as supporting elements saves space in the lighting device.

[0033] In some embodiments, the automotive lighting device includes more than one foldable elongated region.

[0034] In some cases, more than one foldable elongated region is needed because they require a certain thickness for manufacturing considerations and they cannot be fully folded. Therefore, the folding is done in more than one step.

[0035] In some embodiments, the automotive lighting device further includes a solid-state light source.

[0036] The term "solid state" refers to light emitted by a solid-state electroluminescent unit, which uses semiconductors to convert electricity into light. Compared to incandescent lighting, the visible light produced by solid-state lighting has reduced heat generation and less energy dissipation. Compared to fragile glass tubes / glass bulbs and thin filament wires, the generally small size of solid-state electronic lighting devices provides greater impact resistance and vibration resistance. They also eliminate filament evaporation, potentially extending the life of the light-emitting device. Some examples of these types of lighting devices include semiconductor light-emitting diodes (light-emitting diodes, referred to as LEDs), organic light-emitting diodes (organic light-emitting diodes, referred to as OLEDs) or polymer light-emitting diodes (polymer light-emitting diodes, referred to as PLEDs) as light sources, rather than electric filaments, plasmas or gases.

[0037] Regarding another invention aspect, the present invention provides a method for manufacturing the automotive lighting device according to the first invention aspect, the method comprising the following steps:

[0038] designing a mold having a first portion of a support element and a second portion of a support element joined by a foldable elongated region, wherein the foldable elongated region of the mold has a thickness sufficient to allow plastic material to flow therethrough;

[0039] injecting a plastic material into the mold to form the support element;

[0040] demoulding the support element;

[0041] Folding may fold the elongated region to form a closed channel structure.

[0042] The method is advantageous because it provides an easy and reliable way to obtain a lighting device with channels for demisting in different parts of the lighting device. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] To complete the description and for a better understanding of the invention, a set of drawings is provided. Said drawings form an integral part of the specification and illustrate embodiments of the invention, which should not be interpreted as limiting the scope of the invention, but as examples of how the invention may be implemented. The drawings include the following figures:

[0044] Figure 1 A specific embodiment of a supporting element used in the automotive lighting device according to the present invention is shown.

[0045] Figure 2A schematic side view of a vehicle lighting device according to the present invention is shown.

[0046] Figure 3 Some steps of the method for manufacturing the automobile lighting device according to the present invention are shown.

[0047] Figure 4A and Figure 4B Different embodiments of a support element for use in a vehicle lighting device according to the invention are shown.

[0048] Figure 5 A lighting device installed in a motor vehicle according to a specific embodiment of the present invention is shown. DETAILED DESCRIPTION

[0049] Exemplary embodiments are described herein in sufficient detail to enable those skilled in the art to practice the systems and processes described herein. It is important to understand that the embodiments may be provided in many alternative forms and should not be construed as limited to the examples set forth herein.

[0050] Therefore, the embodiments can be modified in various ways and have various alternative forms, and specific embodiments thereof are shown in the drawings and exemplarily described in detail below. It is not intended to be limited to the specific methods disclosed. On the contrary, all modifications, equivalents and alternatives falling within the scope of the appended claims should be included. Throughout the drawings and detailed description, the elements of the exemplary embodiments are consistently represented by the same reference numerals where appropriate.

[0051] Figure 1 A specific embodiment of a supporting element 2 used in a vehicle lighting device according to the present invention is shown.

[0052] The support element 2 comprises a first portion 3 and a second portion 5 joined by a foldable elongated region 7 .

[0053] The first part 3 of the support element 2 comprises a first portion 4 of a channel structure and the second part 5 of the support element 2 comprises a second portion 6 of a channel structure.

[0054] The parts 4 , 6 of the channel structure are configured to cooperate with each other and form a closed channel structure when the second part 5 of the support element 2 is bent over the first part 3 of the support element 2 via the joining area 7 .

[0055] As can be seen from the figure, the resulting channel structure comprises one inlet 11 and two outlets 12 , 13 .

[0056] As in this example, the first part 4 of the channel structure comprises a groove comprising a first end and a second end. The first end comprises an inlet, and the second end is in communication with the rest of the channel structure. Here, a protrusion extends from the second part 5 and has a top surface forming an oblique segment. The protrusion, the oblique segment and the groove are arranged so that when the foldable elongated area 7 is folded, the protrusion is placed into the groove in a spaced manner between the oblique segment and the bottom of the groove, so that the oblique segment closes the groove to form a duct from the inlet 11 to the second end. The duct forms the entry part of the closed channel structure.

[0057] If available from Figure 1 As can be seen, in this example the inlet portion may provide two channel portions extending to the outlets 12 , 13 .

[0058] Figure 2 A schematic side view of a vehicle lighting device 1 according to the invention is shown, which comprises a housing 2 comprising a channel structure with an inlet 11 and outlets 12, 13. A light source 20 can be seen in the background of this view.

[0059] The lighting device further comprises a ventilation element 8 which is positioned in fluid communication with the inlet 11 of the channel structure.

[0060] The lighting device further comprises a fan element 9 arranged to move air into the inlet 11 of the channel structure, thus providing a flow which may improve the demisting performance.

[0061] Figure 3 Some steps of the method for manufacturing the automotive lighting device according to the present invention are shown.

[0062] The first step of the method is to provide a mould 50 comprising a first part 3 of a support element and a second part 5 of a support element joined by a foldable elongated area 7. The size of the foldable elongated area is carefully calculated by mould flow simulation so that the thickness of this part of the mould is sufficient to allow plastic material to flow through.

[0063] Then, plastic material is injected into the mold to form the support element, and once the injection process is completed, the support element is demoulded, thus obtaining a Figure 1 Support elements shown.

[0064] To complete the support element, the foldable elongated region 7 is folded to form a closed channel structure.

[0065] Figure 4A and Figure 4B Different embodiments of a support element for use in a vehicle lighting device according to the invention are shown.

[0066] Figure 4AA wire harness cover 2' is shown which is intended to be placed in a lighting device as an "eyebrow". The wire harness cover 2' comprises a first part 3 and a second part 5 which are joined by a foldable elongated area 7. The first part 3 comprises an inlet 11 and several outlets 12, 13 which are arranged to provide the required ventilation to the outer lens.

[0067] Figure 4B Shows Figure 4A A wiring harness cover in a closed position to be installed in an automotive lighting device.

[0068] Figure 5 A lighting device 1 according to the invention is shown installed in a motor vehicle 100. The motor vehicle lighting device 1 comprises a plurality of LEDs 20 and a harness cover 2' which closes a channel structure having outlets 12, 13 to defog some areas of the lighting device 1.

[0069] As in this example, the outlets 12, 13 can be arranged along the channel structure, and thus along the outer lens. Even if the outer lens is curved as in this example, air can be blown along the outer lens and through the outlets 12, 13.

[0070] The motor vehicle 100 will allow its headlights to be easily defogged without the use of additional channels or active elements, thus maintaining its compact size.

Claims

1. A vehicle lighting device (1), comprising a supporting element (2, 2'), the supporting element comprising a first portion (3), the first portion comprising a first portion (4) of the channel structure; and a second part (5), which comprises a second portion (6) of the channel structure, in, The first part (3) and the second part (5) of the support element (2, 2') are joined by a foldable elongated area (7); When the foldable elongated region (7) is folded to form a closed channel structure, the first portion (4) and the second portion (6) of the channel structure cooperate; The channel structure comprises at least one inlet (11) and at least one outlet (12, 13), and The first part (4) of the channel structure comprises a groove, the groove comprising a first end and a second end, the first end comprising the inlet (11) and the second end communicating with the rest of the channel structure, the second part (6) of the channel structure comprises an oblique section extending from the second part (5) and arranged such that when the foldable elongated region (7) is folded, the oblique section closes the groove to form a duct from the inlet to the second end, the duct forming an entry portion of the closed channel structure; The second part (6) of the channel structure comprises a protrusion, the oblique section being the surface of the protrusion, the protrusion being arranged to be placed in the groove in a manner spaced apart between the oblique section and the bottom of the groove so as to form the duct.

2. The vehicle lighting device according to claim 1, characterized in that: The channel structure comprises two or more outlets (12, 13).

3. The automotive lighting device according to claim 1, characterized in that: The automotive lighting device (1) comprises an outer lens, the at least one outlet (12, 13) being arranged to provide ventilation to the outer lens.

4. The automotive lighting device according to claim 3, characterized in that: The outlets (12, 13) are arranged to provide ventilation to different positions of the outer lens.

5. The automotive lighting device according to claim 3, characterized in that: The support element (2') is arranged as an "eyebrow" in the lighting device (1), so that one or more outlets (12, 13) can realize ventilation of the outer lens.

6. The automotive lighting device according to claim 1, characterized in that: Also included is a ventilation element (8) positioned in fluid communication with the inlet (11) of the channel structure.

7. The vehicle lighting device (1) according to claim 1, characterized in that: Also included is a fan element (9) arranged to move air into the inlet of the channel structure.

8. The vehicle lighting device (1) according to claim 1, characterized in that: The supporting element is made of plastic injection.

9. The vehicle lighting device (1) according to claim 1, characterized in that: The supporting element is a decorative frame.

10. The vehicle lighting device (1) according to claim 1, characterized in that: The supporting element is a shell (2).

11. The vehicle lighting device (1) according to claim 1, characterized in that: The supporting element is a wiring harness cover (2').

12. The vehicle lighting device (1) according to claim 1, characterized in that: Also included are more than one foldable elongated region (7).

13. The vehicle lighting device (1) according to claim 1, characterized in that: Also included is a solid state light source (20).

14. A method for manufacturing a vehicle lighting device according to any one of the preceding claims, the method comprising the following steps: designing a mould (50) having a first portion (3) of a support element and a second portion (5) of a support element joined by a foldable elongated region (7), wherein the thickness of the foldable elongated region of the mould is sufficient to allow plastic material to flow through; injecting plastic material into the mould to form the support element (2, 2'); demoulding the support element (2, 2'); and Folding can fold the elongated region (7) to form a closed channel structure.

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