Method for manufacturing a housing surrounding a controller

Abstract

The invention relates to a method for manufacturing a housing (7) surrounding a control unit (8) by mechanically forming a raw material (1), wherein the control unit (8) is particularly designed to control a motor vehicle headlight, the method comprising the following steps: a) providing a substantially strip-shaped raw material (1), wherein the raw material (1) is divided into at least three mutually adjacent sub-regions (4, 5, 6) which are separated by folding axes (11, 13); b) forming cooling ribs (4a) in a first sub-region (4); c) forming a housing bottom (5a) in a second sub-region (5); d) forming a housing bottom (5a) in a second sub-region (5); The present invention relates to a method for manufacturing a housing cover (6a) at a third sub-region (6); e) forming a housing cover (6a) at the third sub-region (6); e) performing a folding process in which the first sub-region (4) is folded onto the second sub-region around a first folding axis (11); f) installing a controller (8) at the second sub-region (4); g) performing a folding process in which the third sub-region (6) is folded onto the second sub-region around a second folding axis (13); h) fixing the first sub-region (4) at the second sub-region (5) and fixing the second sub-region (5) at the third sub-region (6) using at least one fixing device (16).

Description

Technical Field

[0001] The invention relates to a method for producing a housing surrounding a control unit by mechanical forming of a raw material, wherein the control unit is designed in particular for controlling a motor vehicle headlight.

[0002] Furthermore, the invention relates to a control module.

[0003] Furthermore, the invention relates to a motor vehicle headlight. Background Art

[0004] In the prior art, control units for motor vehicle headlamps are usually surrounded by a housing. In order to dissipate the heat generated in the control unit, the known housing is usually equipped with cooling devices, such as cooling ribs, on the outside of the housing. For this purpose, the cooling ribs have to be connected to the housing, wherein a heat-conducting adhesive is used for this purpose, which has a certain curing time. Current efforts to optimize the cooling of the housing of the control unit involve improving the material selection for the housing and the cooling ribs, changing the housing dimensions relative to the dimensions of the cooling ribs, or using fast-curing adhesives. Summary of the invention

[0005] The object of the present invention is to provide a possibility to overcome the disadvantages of the prior art.

[0006] This object is achieved by a method according to the invention, which comprises the following method steps:

[0007] a) providing an approximately strip-shaped, preferably metallic starting material having an upper side and an underside, wherein the starting material is divided into at least three mutually adjacent sub-regions which are separated by a folding axis;

[0008] b) forming cooling ribs at a first sub-region of the raw material (after step a);

[0009] c) forming the housing bottom at a second subregion of the raw material, which second subregion preferably corresponds to a middle region of the raw material, wherein the raw material has a first folding axis between the first subregion and the second subregion (after step a);

[0010] d) forming the housing cover at a third sub-region of the raw material, wherein the raw material has a second folding axis between the second sub-region and the third sub-region (after step a);

[0011] e) carrying out a folding process in which the bottom side of the first subregion of the raw material is folded about a first folding axis onto the bottom side of the second subregion of the raw material so that in the folded state the first subregion and the second subregion are oriented approximately overlapping one another, wherein the bottom side of the first subregion and the bottom side of the second subregion directly contact one another, preferably at least in sections over the entire surface (after steps b and c);

[0012] f) attaching a control unit on the upper side of the second sub-region of the raw material, which control unit is configured in particular to control a motor vehicle headlight (after step c);

[0013] g) carrying out a folding process in which the upper side of the third subregion of the raw material is folded about a second folding axis onto the upper side of the second subregion of the raw material, or carrying out a folding process in which the lower side of the third subregion of the raw material is folded about a second folding axis onto the upper side of the second subregion of the raw material, so that in the folded state the second subregion and the third subregion are oriented approximately overlapping one another, wherein the housing bottom formed in step c) and the housing cover formed in step d) are designed such that in the folded state one above the other a housing chamber enclosing the control is formed between the housing bottom and the housing cover (after step f);

[0014] h) fixing the first sub-region to the second sub-region and / or fixing the second sub-region to the third sub-region using at least one fixing device, so that the first sub-region and the second sub-region and / or the second sub-region and the third sub-region are connected to each other through the cooperation of the fixing devices (after steps e and g).

[0015] Unless otherwise specified, the chronological order of the method steps described in claim 1 can be freely selected. For example, the chronological order of steps b, c, d can also be b, d, c or c, b, d or c, d, b or d, b, c or d, c, b. As raw material, steel, high-grade steel or aluminum is provided, for example. The person skilled in the art selects a raw material in this regard, i.e., the raw material allows plastic forming and plastic folding without breaking. The raw material is preferably strip-shaped, wherein the raw material has, for example, a length of 25 cm to 75 cm, a width of 6 cm to 20 cm and a thickness of 0.3 mm to 2 mm. At the folding axis, the raw material can have a reduced thickness compared to the first, second and third sub-areas in order to facilitate the folding process. The shaping of the cooling ribs at the first sub-area of ​​the raw material comprises, in particular, mechanical shaping, such as extrusion of the first sub-area toward a corresponding contour. The shaping of the housing bottom or the housing cover at the second or third sub-area of ​​the raw material comprises, in particular, the shaping of at least one recess at the second and / or third sub-area, wherein the recess can have a shape having a spatial extension that is at least equal to or greater than the spatial extension of the controller. The folding process according to steps e) and g) comprises a mechanical folding of the raw material, wherein preferably a folding tool is placed against the corresponding folding axis and the folding process is then carried out. In this process, the raw material is plastically deformed. After the folding process according to step e), the cooling ribs are preferably in direct contact with the housing bottom at least in sections in order to achieve efficient cooling of the housing bottom. After the cooling ribs, the housing bottom and the housing cover have been formed, the first, second and third sub-areas of the raw material preferably have the same length and / or width. The controller can also be set up to control a motor vehicle motor, a motor vehicle transmission, a running gear of a motor vehicle or a hydraulic device, for example for construction machinery or agricultural machinery.

[0016] Preferably, the first sub-region is adjacent to the second sub-region and the second sub-region is adjacent to the third sub-region, so that the second sub-region is arranged between the first and third sub-regions, or the second sub-region is adjacent to the first sub-region and the first sub-region is adjacent to the third sub-region, so that the first sub-region is arranged between the second and third sub-regions. In particular, in the unfolded state, the first sub-region does not adjoin the third sub-region or the second sub-region does not adjoin the third sub-region.

[0017] At least one fixing means can be designed as at least one folded tab, a riveted connection, a welded connection, a latching connection or an adhesive connection. At least one hole for the rivet connection can be introduced into the raw material before or after the folding process. At least one folded tab can be formed, for example, at the edge region of the first and / or second and / or third subregion. After the first and / or second folding process, at least one tab can be folded so that at least one tab formed at the edge region of a subregion at least partially surrounds the other subregion after it has been folded. Alternatively to this, a latching connection can also be provided, wherein at least one latching nose is formed at a subregion of the raw material and a corresponding recess, into which the latching nose can be locked, is formed at the other subregion. If the subregion is folded onto the other subregion according to steps e) and g), the latching nose can be locked into the corresponding recess.

[0018] The at least one fixing means may in particular comprise a first and a second fixing means, wherein the first fixing means fixes the first subregion at the second subregion and the second fixing means fixes the second subregion at the third subregion. The first and second fixing means may be identical or different. The fixing means may also fix the first subregion at the third subregion, so that the second subregion, which in the folded state of the raw material is arranged in the vertical direction between the first and third subregions, is fixed in a sandwich-like manner by the first and third subregions.

[0019] Preferably, the second fixing means is designed as an adhesive connection, which fixes the housing bottom to the housing cover and is designed to seal the housing chamber. Thus, the housing cover can be advantageously fixed to the housing bottom and at the same time the housing is sealed and thus protected from possible contamination. The adhesive connection is preferably an adhesive layer, which is applied as a closed adhesive bead, for example, along the edge region of the second and / or third subregion of the starting material before the folding process.

[0020] In particular, the method can comprise the following further steps (temporally) after step c) and before installing the controller according to step f):

[0021] A filling material is arranged between the control unit and the second partial region, wherein the filling material comprises a heat-conducting adhesive, in particular a silicone-containing or silicone-free paste-like heat-conducting adhesive.

[0022] The filling material can advantageously facilitate the dissipation of heat generated by the control unit. The filling material can also improve contact and adhesion of the control unit at the second sub-region.

[0023] Preferably, the control unit comprises a printed circuit board with an electronic circuit arranged thereon for operating the motor vehicle headlights, wherein the filling material is arranged in particular between the printed circuit board and the second partial region.

[0024] In order to achieve particularly efficient heat dissipation from the control unit to the cooling ribs, it is advantageous if the filling material has a thermal conductivity of greater than 1 W / mK, preferably greater than 5 W / mK, particularly preferably greater than 10 W / mK.

[0025] Preferably, the starting material comprises a metal strip, wherein the metal has mechanical properties which allow a plastic and break-free folding process according to method steps e) and g).

[0026] Particularly preferably, the starting material consists of a single metal strip. As a result, the housing of the control unit is advantageously constructed substantially in one piece. In other words, the cooling device, the housing bottom and the housing cover, which substantially form the housing, are formed from a single metal strip. As a result, the manufacturing process can be carried out more advantageously and more quickly.

[0027] According to the invention, a control module is provided, which comprises a control unit, which is particularly designed to control a motor vehicle headlight, and a housing, wherein the housing is manufactured according to the method according to the invention. The control unit can also be designed to control a motor vehicle engine, a motor vehicle transmission, a running gear of a motor vehicle or a hydraulic device, for example for a construction machine or an agricultural machine.

[0028] According to the invention, a motor vehicle headlight is provided which comprises a control module according to the invention.

[0029] In the context of the present description, the terms “upper”, “lower”, “horizontal” and “vertical” are to be understood as indicating the orientation of the motor vehicle headlight when it is arranged in the normal position of use after it has been installed in the motor vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Next, the present invention is further described based on a preferred embodiment (however, the present invention should not be limited to this embodiment).

[0031] Figure 1 A side view and a top view of a raw material having first, second and third sub-regions are shown;

[0032] Figure 2 shows a side view and a top view of the raw material after a first folding process;

[0033] Figure 3 Shown according to Figure 2 A side view and a top view of the raw material and a controller installed at the second sub-area;

[0034] Figure 4shows a side view and a top view of the raw material after the second folding process;

[0035] Figure 5 A second embodiment of a starting material is shown, which has a first, a second and a third partial region in an alternative arrangement; and

[0036] Figure 6 A third embodiment of a starting material is shown, which has a first, a second and a third partial region in a further alternative arrangement. DETAILED DESCRIPTION

[0037] Figure 1 A substantially strip-shaped, preferably metallic raw material 1 is shown, which has an upper side 2 and a lower side 3, wherein the raw material 1 is divided into three equally large, mutually adjacent sub-areas 4, 5, 6 in the illustrated embodiment, which are separated by a folding axis. The first sub-area 4 is adjacent to the second sub-area 5 and the second sub-area 5 is adjacent to the third sub-area 6, so that the second sub-area 5 is arranged between the first sub-area 4 and the third sub-area 6. The raw material 1 is formed into a housing 7 surrounding a controller 8 by mechanical forming and folding. For this purpose, the raw material 1 is preferably a metal strip, wherein the metal has mechanical properties that allow a plastic and fracture-free forming-and folding process. In the illustrated embodiment, the raw material 1 consists of a single metal strip. Cooling ribs 4a are formed at the first sub-area 4 of the raw material 1, wherein the cooling ribs 4a are formed by mechanical forming (for example, by extruding the first sub-area 4 toward a corresponding contour). A housing bottom 5a is formed at the second sub-area 5 of the raw material 1. The second sub-area 5 corresponds to the middle area of ​​the raw material 1, wherein the raw material has a first folding axis 11 between the first sub-area 4 and the second sub-area 5. A housing cover 6a is formed on the third subregion 6 of the raw material 1, wherein the raw material 1 has a second folding axis 13 between the second subregion 5 and the third subregion 6. The housing bottom 5a and the housing cover 6a are formed, for example, by mechanical pressing of the respective subregions onto the respective contours.

[0038] Figure 2 The raw material 1 is shown after a first folding process. The bottom side 3 of the first sub-region 4 of the raw material 1 is folded about a first folding axis 11 onto the bottom side 3 of the second sub-region 5 of the raw material 1. In the folded state, the first sub-region 4 and the second sub-region 5 are oriented approximately overlapping one another, wherein the bottom side 3 of the first sub-region 4 and the bottom side 3 of the second sub-region 5 are in direct contact with one another.

[0039] Figure 3The raw material 1 is shown after method step f). A control unit 8, which is particularly designed to control a motor vehicle headlight, is fixed to the upper side 2 of the second sub-region 5 of the raw material 1. The fixing of the control unit 8 to the second sub-region 5 is realized, for example, by means of rivets and / or adhesive. The control unit 8 comprises a circuit board 14 with an electronic circuit (not shown) for operating the motor vehicle headlight installed thereon. A filling material 15 is arranged between the circuit board 14 of the control unit 8 and the second sub-region 5. The filling material 15 is a heat-conducting adhesive, in particular a silicone-containing or silicone-free paste-like heat-conducting adhesive.

[0040] Figure 4 The raw material 1 is shown after the second folding process. The upper side 2 of the third sub-region 6 of the raw material 1 is folded around the second folding axis 13 onto the upper side 2 of the second sub-region 5 of the raw material 1. In the folded state, the second sub-region 5 and the third sub-region 6 are oriented approximately overlapping one another. The housing bottom 5a and the housing cover 6a are designed such that, in the folded state one above the other, a housing chamber enclosing the controller 8 is formed between the housing bottom 5a and the housing cover 6a.

[0041] The first sub-area 4 utilizes (in Figure 2 The first fixing means 16a (shown in FIG. 1 ) is fixed to the second sub-region 5. In addition, the second sub-region 5 is fixed to the second sub-region 5 by means of (in FIG. Figure 3 The second fixing device 16b (shown in FIG. 1 ) is fixed to the third sub-region 6, so that the first sub-region 4 and the second sub-region 5 and the second sub-region 5 and the third sub-region 6 are firmly connected to each other through the joint action of the first fixing device 16a and the second fixing device 16b. The first fixing device 16a and the second fixing device 16b can be designed identically or differently. Generally, the fixing device 16 can be constructed as at least one folded plate, a riveted connection, a welded connection, a latching connection or an adhesive connection, for example. Figure 2 As can be seen in FIG. 1 , the first fixing means 16 a is designed as a riveted connection, wherein eight holes 17 for rivets are provided. Figure 3 As can be seen in the figure, the second fixing means 16b is designed as an adhesive connection, wherein the adhesive connection extends as a closed adhesive path 18 along the edge area of ​​the housing bottom 5a. The adhesive path 18 can also be provided on the housing cover 6a as an alternative or in addition. The fixing means 16 can also fix the first sub-area 4, the second sub-area 5 and the third sub-area 6 to each other. For example, at least one hole 17 for a riveted connection can be provided through all sub-areas 4, 5, 6.

[0042] Figure 5A second embodiment is shown, in which the cooling ribs 4a are arranged between the housing bottom 5a and the housing cover 6a. When folding the starting material 1, the bottom 3 of the first sub-region 4 of the starting material 1 is folded about the first folding axis 11 onto the bottom 3 of the second sub-region 5 of the starting material 1. In other words, the housing bottom 5a is folded onto the cooling ribs 4a. In a second step, the bottom 3 of the third sub-region 6 of the starting material 1 is folded about the second folding axis 13 onto the top 2 of the second sub-region 5 of the starting material 1. In other words, the housing cover 6a is folded onto the side of the housing bottom 5a facing away from the cooling ribs 4a.

[0043] Figure 6 A further embodiment is shown in which the three subregions 4 , 5 , 6 of the starting material 1 have an L-shaped arrangement.

[0044] List of Reference Numerals

[0045] 1 raw materials

[0046] 2 upper side

[0047] 3 Lower side

[0048] 4 The first sub-area

[0049] 4a Cooling ribs

[0050] 5 Second sub-area

[0051] 5a Housing bottom

[0052] 6 The third sub-area

[0053] 6a Housing cover

[0054] 7 Housing

[0055] 8 Controller

[0056] 11 First folding axis

[0057] 13 Second folding axis

[0058] 14 Circuit Board

[0059] 15 Filling material

[0060] 16 Fixing device

[0061] 16a First fixing device

[0062] 16b Second fixing device

[0063] 17 holes

[0064] 18 Adhesive Road.

Claims

1. A method for producing a housing (7) surrounding a controller (8) by mechanical forming of a raw material (1), wherein: The controller (8) is configured to control a motor vehicle headlamp. It is characterized by the following steps: a) providing a strip-shaped metallic raw material (1) having an upper side (2) and an underside (3), wherein the raw material (1) is divided into at least three mutually adjacent sub-regions (4, 5, 6) which are separated by folding axes (11, 13); b) forming cooling ribs (4a) at a first sub-region (4) of the raw material (1); c) forming a shell bottom (5a) at a second sub-region (5) of the raw material (1), the second sub-region corresponding to a middle region of the raw material (1), wherein the raw material (1) has a first folding axis (11) between the first sub-region (4) and the second sub-region (5); d) forming a housing cover (6a) at a third sub-region (6) of the raw material (1), wherein the raw material (1) has a second folding axis (13) between the second sub-region (5) and the third sub-region (6); e) carrying out a folding process in which the bottom side (3) of the first sub-region (4) of the raw material (1) is folded about the first folding axis (11) onto the bottom side (3) of the second sub-region (5) of the raw material (1), so that in the folded state the first sub-region (4) and the second sub-region (5) are oriented so as to overlap one another, wherein the bottom side (3) of the first sub-region (4) and the bottom side (3) of the second sub-region (5) are in direct contact with one another, at least in sections, over the entire surface; f) the controller (8) is arranged on the upper side (2) of the second sub-region (5) of the raw material (1), and is configured to control a motor vehicle headlamp; g) performing a folding process in which the upper side (2) of the third sub-region (6) of the raw material (1) is folded about the second folding axis (13) onto the upper side (2) of the second sub-region (5) of the raw material (1), or performing a folding process in which the lower side (3) of the third sub-region (6) of the raw material (1) is folded about the second folding axis (13) onto the upper side (2) of the second sub-region (5) of the raw material (1), so that in a folded state the second sub-region (5) and the third sub-region (6) are oriented so as to overlap one another, wherein the housing bottom (5a) formed in step c) and the housing cover (6a) formed in step d) are constructed so that in a state in which they are folded one above the other, a housing chamber surrounding the controller (8) is formed between the housing bottom (5a) and the housing cover (6a); h) using at least one fixing device (16) to fix the first sub-region (4) to the second sub-region (5) and / or to fix the second sub-region (5) to the third sub-region (6), so that the first sub-region (4) and the second sub-region (5) and / or the second sub-region (5) and the third sub-region (6) are connected to each other through the joint action of the at least one fixing device (16).

2. The method according to claim 1, wherein: The first sub-region (4) is adjacent to the second sub-region (5) and the second sub-region (5) is adjacent to the third sub-region (6), so that the second sub-region (5) is arranged between the first sub-region (4) and the third sub-region (6), or the second sub-region (5) is adjacent to the first sub-region (4) and the first sub-region (4) is adjacent to the third sub-region (6), so that the first sub-region (4) is arranged between the second sub-region (5) and the third sub-region (6).

3. The method according to claim 1, wherein: The at least one fastening means (16) is designed as a folded web, a riveted connection, a welded connection, a latching connection or an adhesive connection.

4. The method according to claim 3, wherein: The at least one fixing device (16) comprises a first fixing device (16a) and a second fixing device (16b), wherein the first fixing device (16a) fixes the first sub-region (4) at the second sub-region (5) and the second fixing device (16b) fixes the second sub-region (5) at the third sub-region (6).

5. The method according to claim 4, wherein: The second fixing means (16b) is designed as an adhesive connection which fixes the housing bottom (5a) to the housing cover (6a) and is provided to seal the housing chamber.

6. The method according to any one of claims 1 to 5, wherein: The method comprises the following further steps after step c) and before installing the controller (8) according to step f): A filling material (15) is arranged between the controller (8) and the second sub-area (5), wherein the filling material (15) comprises a silicone-containing or silicone-free paste-like heat-conducting adhesive.

7. The method according to claim 6, wherein: The control unit (8) comprises a circuit board (14) with an electronic circuit installed thereon for operating the motor vehicle headlight, wherein the filling material (15) is arranged between the circuit board (14) and the second sub-region (5).

8. The method according to claim 6, wherein: The filling material (15) has a thermal conductivity greater than 1 W / mK.

9. The method according to any one of claims 1 to 5, wherein: The starting material (1) comprises a metal strip, wherein the metal has mechanical properties which allow a plastic and break-free folding process according to method steps e) and g).

10. The method according to any one of claims 1 to 5, wherein: The raw material (1) consists of a single metal strip.

11. A control module comprising a controller (8) configured to control a motor vehicle headlamp and a housing (7) surrounding the controller, characterized in that: The housing (7) is produced by the method according to any one of claims 1 to 10.

12. A motor vehicle headlamp comprising the control module according to claim 11.

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