Lamp holder, LED module comprising lamp holder, and method for producing lamp holder

Abstract

A socket (10) for a replaceable LED module comprises: a seating and receiving section (1) extending along a first axis (100) for seating in a housing of a headlamp and for receiving an electronic component comprising at least one LED; a plug-in connector section (5) extending along a second axis (200) for connection with an external coupler that can provide a power supply source; and at least one contact line, a first end of which extends along a first axis (100) into the seating and receiving section (1) in order to be connectable thereto after installation of the electronic component, and a second end of which extends along a second axis (200) in the plug-in section (5) in order to be connectable thereto, when the plug-in connection is closed, the plug-in connection is connected with the coupler-side contact terminal, so that the electronic component is supplied with electric power. The first axis (100) and the second axis (200) enclose an angle to each other. The at least one contact line comprises a first contact pin (41, 42) and a second contact pin (71, 72) different from the first contact pin (41, 42), the first contact pin (41, 42) forming a first end and the second contact pin (71, 72) forming a second end, the two contact pins (41, 42; 71, 72) are electrically conductively connected to each other.

Description

[0001] This application claims the priority of German Patent Application 10 2022 210 933.3 filed on October 17, 2022, the disclosure of which is hereby incorporated by reference into this application. Technical Field

[0002] Different aspects and embodiments relate to lamp sockets for replaceable LED modules, especially for use in vehicle headlights. Furthermore, the invention relates to corresponding LED modules and methods for manufacturing or assembling lamp sockets. Background Art

[0003] LED modules are being used more and more widely in the field of vehicle lights and headlights. Depending on the application, high-performance LEDs are also used here. A recently proposed platform that can also meet the standards established by the International Electrotechnical Commission (IEC) is the replaceable LED signal lamp, abbreviated as XLS (e X changeable L ED S ignal lamp). Meeting the standards of UN / ECE Regulation No. 128 ("Light-emitting diode light sources (LED light sources)") allows for a uniform construction, but there are possible variations in lighting devices, i.e., depending on the different combinations and arrangements of LEDs in the module for use and application. These different applications can be, for example, daytime running lights, indicator lights, brake lights, or additional functions such as fog lights, high beams, etc.

[0004] Such LED modules typically have electronic components, which include: an LED driver and one or more LEDs; an installation and accommodation section extending along the module axis for installation in the headlight housing and for accommodating the electronic components including one or more LEDs; and also a connector section for connection to an external coupler that can provide a vehicle-side power supply source.

[0005] However, as in the case of halogen lamp series (such as H7, H8, H9, etc.; UN / ECE Regulation No. 37: "Approved incandescent lamps for motor vehicles and their trailers") that have been standardized for use in the field of motor vehicles, different types of lamp sockets also result in LED modules depending on the application and structural requirements. Due to insufficient structural space in the vehicle, it may be necessary to bend the original axial construction of the lamp or module by 90° in the area of the corresponding connector section in order to keep the total length of the lamp socket or lamp / module within the limit. In the case of halogen lamps, this especially relates to base types PGJ19-1 (H8) and PGJ19-5 (H9), for example. However, the situation in LED modules also seems similar. The vehicle-side cable coupler providing power supply is plugged onto the connector section laterally or perpendicular to the lamp axis here.

[0006] LED modules typically (such as the applicant's XLS-LED module) have contact conductors configured as pins, with the first end of each of the contact conductors extending along a longitudinal axis into a placement and accommodation section so as to be connectable to an electronic component that will be accommodated in the module on the end side after installation, and the second end of the contact conductor extending oppositely into a connector section so as to be connected to a contact terminal on the coupler side when the plug connection is closed, such that electrical power is supplied to the electronic component as a whole. In the normal case, there are two or more such pin-type contact conductors (at least for voltage and reference potential, etc.).

[0007] Unlike metal wires insulated by a sheath, the contact pins (such as steel, aluminum, or copper) are provided with a certain thickness such that although they are bendable, they remain undeformed under the conditions of use. Due to the stable guidance through the lamp socket (usually in the axial direction), the contact pins generally do not require an insulating sheath to avoid mutual contact and thus short circuits, even when there is an injection molding encapsulation that itself contributes to insulation. However, the injection molding encapsulation generally stipulates precise positioning and mutual spacing between the contact conductors or contact pins to avoid electrical faults.

[0008] However, in the case of a specific lamp socket with a 90° bend or deflection in the connector section of the LED module with contact pins described above, the contact pins must follow this bend. To achieve this, the contact pins are first bent at 90° in a specific process before the injection molding encapsulation, which incurs costs. In addition, since the tolerances in the connector area and in the area connected to the electronic component are very small, and the corresponding molding process of the contact pins may be defective, measurements are regularly required to ensure quality, which means additional effort.

[0009] Therefore, there is a need to save costs and reduce the effort during the installation of the lamp socket. SUMMARY OF THE INVENTION

[0010] To solve these problems or other related problems, one aspect of the present invention is based on a lamp socket for a replaceable LED module, the lamp socket including a placement and accommodation section extending along a first axis and a connector section extending along a second axis for connection to an external coupler that can provide a power supply source. The placement and accommodation section is for placement in the housing of a headlight and for accommodating an electronic component including at least one LED (light-emitting diode). The term LED should be understood broadly and generally can include semiconductor light-emitting mechanisms, and also, for example, laser diodes, etc.

[0011] Furthermore, the lamp socket includes at least one, preferably at least two, contact conductors, the first ends of which extend along a first axis into the receiving and accommodating section so as to be connectable to the electronic component after installation thereof, and the second ends of which extend along a second axis in the plug section so as to be connected to the contact terminals on the coupler side in the case of a closed plug connection there, such that electrical power is supplied to the electronic component. Similar to what was described at the beginning, the lamp socket considered here has a deflection or bend, i.e., the first axis and the second axis enclose an angle (different from 180°) with each other. The angle is the deflection angle.

[0012] According to an aspect, it is now proposed that at least one contact conductor includes a first contact pin and a second contact pin different from the first contact pin. Thus, there are at least two contact pins. Other pin-shaped extensions in the plug or in the region of the electronic component are not excluded. The first contact pin forms the first end of the contact conductor composed of it and the second contact pin, and the second contact pin forms the second end of the contact conductor. The two contact pins are conductively connected to each other here so as to be able to convey the electrical power provided by the corresponding contact terminals of the coupler to the electronic component and thus to the LED.

[0013] With the above configuration, it can be achieved that the additional process of bending the contact pins can be eliminated, so that production time, logistics and costs are saved. The same also applies to the subsequent measurement, which can now be eliminated because the existing non-bent contact pins can be integrated with high precision. The deflection or bend is now achieved by the electrical contact between the contact pins that are at an angle to each other but can themselves be manufactured linearly. The additional costs associated with their mutual positioning and contact are offset by the savings. The angle can particularly be 90°, but other angles are also possible.

[0014] According to a specific aspect of the invention, the receiving and accommodating section and the plug section can be configured as physically separate sections, which are configured to be mechanically joined together by installation, preferably by plugging the plug section onto the receiving and accommodating section.

[0015] This enables the two sections to be manufactured separately, and the corresponding contact pins are introduced into the respective sections as simple non-bent components (straight metal pins). The deflection of the assembled contact conductor at the above-mentioned angle is exhibited when the two sections are assembled. The contact pins are integrated in the plug section or the receiving and accommodating section such that they contact each other during assembly, or their mutual spacing is small such that they can be conductively connected by known joining methods such as soldering, bonding, welding, etc. The precision can be simply achieved.

[0016] A refined improvement of the above aspect proposes that the placement and accommodation section includes an injection molded part, in which the first contact pin is fixed by injection encapsulation. Alternatively or additionally, the connector section can also include an injection molded part, in which the second contact pin is then fixed by injection encapsulation. Here, the particular advantage is obvious: the contact pins can be integrated into the injection encapsulation with high precision respectively. In addition, the cost of injection encapsulation for the second contact pin that forms a separate part is significantly smaller compared to the injection encapsulation of only one part but together with the previous bending and measuring processes.

[0017] Advantageously, in this aspect, the two contact pins can be formed substantially linearly respectively, that is, no prior processing is required.

[0018] However, this does not exclude that the two contact pins are conductively connected to each other at the contact part, where at least one of the two contact pins, preferably both contact pins, is bent in the region of the contact part. This bending allows, on the one hand, better and space-saving positioning of the parallelly arranged pins with a defined spacing from each other (if there are two first and second contact pins respectively, then through the bending part, the two pairs can achieve the same mutual spacing, for example, to comply with the regulations regarding this). And on the other hand, it allows an optimized contact part, because the mutually facing surfaces of the contact pins can be increased thereby, which can in turn improve the contact by methods such as welding or soldering.

[0019] According to an embodiment, the two contact pins are conductively connected to each other at the contact part, where the contact part is exposed in a groove formed in the injection molded part of the connector section and is externally accessible. This state only needs to last during manufacturing, and then the groove can optionally be filled with casting material. Alternatively or additionally, the groove can be closed by a cover to protect the contact part from external influences. The groove can enable, for example, a channel for a welding laser to the contact pins that are in a closely contacting state and are angled with each other, more precisely, in the state where the placement and accommodation section and the connector section are fully plugged or assembled. Alternatively, it can be proposed that the groove is provided on the side of the placement and accommodation section, and the contact part appears there during assembly rather than in the plugging section.

[0020] According to another embodiment, the contact part or the connection part between the two contact pins is formed by laser welding, soldering process or applying a conductive adhesive. However, other possibilities are not excluded, nor is it excluded that the two pins are injection encapsulated (spatially) such that they form contact only under the mechanical stress of each other when the placement and accommodation section and the connector section are assembled, which is equivalent to a plug connection. The groove is not required in this case. It also includes that an additional conductive metal part for connection is provided in the connector section. The conductive metal part is regarded as associated with one or the other contact pin within the scope of the text discussed herein.

[0021] On the other hand, it is proposed that the connector section and the receiving and accommodating section have positioning mechanisms that are matingly matched with each other such that when the connector section is plugged onto the receiving and accommodating section during installation, the contact pins come into contact with each other or there is a small spacing. Such mechanisms, for example, mating protrusions and grooves, can be established with sufficient precision by injection molding. According to an improvement, the groove for laser welding of the contact part mentioned above can be combined with such a groove for positioning (a closure on one side of the through-hole in which the contact pins come into contact, from the side of the receiving and accommodating section by the positioning mechanism).

[0022] On the other hand, it is proposed that the connector section has a through-hole formed in the corresponding injection molded part that is different from the groove (if any), and the receiving and accommodating section has a corresponding bolt in the corresponding injection molded part that is matched to the hole. The length of the bolt is greater than the length of the through-hole so that in the plugged-together state, a part of the bolt that protrudes from the hole is formed, and this part is fixed for fixing the connector section, preferably by thermocompression bonding, adhesion, screwing, or riveting at the receiving and accommodating section. The fixing possibility that is compatible with the injection molded part and is very efficient allows further process simplification and cost savings, while being very reliable and temperature stable. Alternatively, the connection between the connector section and the injection molded part can be established by means of adhesion, screwing, riveting, etc.

[0023] According to another embodiment, the receiving and accommodating section includes, in addition to at least one first contact pin and the injection molded part, a metal body that is at least partially injection molded and encapsulated by the injection molded part. The metal body has a flat receiving surface for carrying a substrate of an electronic component at the end side and a plurality of annularly arranged cooling ribs in the direction opposite to the first axis, and the cooling ribs at least partially surround the internal space into which the connector section is inserted in the direction of the first axis after being mounted on the injection molded part of the receiving and accommodating section. This aspect advantageously allows the implementation of the invention aspects detailed above in a module that is compatible with the XLS series. In this design, heat is guided in the backward direction to the protruding ribs and dissipated there through the injection molded and encapsulated metal part that contacts the electronic component via the end-side receiving surface (optionally with a thermal conductive pad or thermal conductive paste between them). Its annular arrangement now just allows a two-piece implementation of the lamp socket in such a way that the connector section is, for example, guided axially from the rear into the internal space formed by the cooling ribs and plugged onto the receiving and accommodating section.

[0024] Improvement solutions in different aspects relate to the design of the mounting and receiving section. The mounting and receiving section has a substantially cylindrical section at the end side, and the central axis of the mounting and receiving section coincides with the first axis, wherein at least one locking and / or key element is formed as a protruding section on the side surface of the cylindrical section. The design solution also corresponds to an advantageous combination of the inventive aspect with the functions known from the construction of LED modules according to the XLS series. With one or more locking sections, the LED module can be replaceably fixed in the headlight socket (housing) according to the type of snap closure. With the key element, it is possible to prevent the installation of a mismatched module type into the relevant headlight.

[0025] Similarly, the connector section can also have at least one key element, which is determined to cooperate with the key element of a matching coupler (electric power supply device) to be plugged in.

[0026] In addition, the connector section can have at least one locking element, which can achieve a releasable mechanical connection with the clutch to be plugged in. This improves the reliability of the connection.

[0027] Aspects of the present invention also propose an LED module. The LED module includes a lamp socket according to one of the above aspects or embodiments or improvement solutions, and an electronic component including at least one LED. The electronic component is received in the mounting and receiving section of the lamp socket and is conductively connected to the first contact pin. The same advantages as described above are obtained.

[0028] The LED module can be an LED-based signal lamp that meets the technical requirements of UN / ECE Regulation No. R128 (United Nations Economic Commission for Europe (UNECE) Regulation No. 128 - Uniform provisions concerning the approval of light-emitting diode light sources (LED light sources) for use in approved headlamps and lamps of motor vehicles and their trailers), issued on December 17, 2018, downloaded on October 13, 2022:

[0029] https: / / www.beuth.de / de / verwaltungsvorschrift / eu-2018-ece128 / 300793218.

[0030] On the other hand, it relates to a method for manufacturing a lamp socket as described in the aspects or embodiments or improvement solutions proposed above. The following steps are proposed:

[0031] - Provide at least one first and second contact pin each;

[0032] - Injection-mold and encapsulate the first and second contact pins separately and separately from each other to form corresponding to the mounting and receiving section and the connector section;

[0033] - A contact portion between the first and second contact pins by laser fusion welding, brazing, or bonding with a conductive adhesive.

[0034] The same advantages as described above are also obtained here.

[0035] Other advantages, features, and details of each aspect are derived from the claims, the description of the preferred embodiments below, and the accompanying drawings. In the drawings, the same reference numerals denote the same features and functions. Description of the Drawings

[0036] The accompanying drawings show:

[0037] Figure 1 A perspective view of the lamp module before assembly according to an embodiment of the present invention;

[0038] Figure 2 Showing the placement of the electronic device in Figure 1 A partial perspective view of the first inner housing portion;

[0039] Figure 3 Showing Figure 2 A perspective view of the state after the placement in and the installation direction to the pipe profile;

[0040] Figure 4 Showing Figure 3 A perspective view of the installation state in;

[0041] Figure 5 Showing Figure 7 A perspective view of the cross-section along the section line B - B in the longitudinal direction of, showing the contact of the lower side of the carrier element with the inner side of the pipe profile.

[0042] Figure 6 Showing Figure 3 A perspective view of the installation state in;

[0043] Figure 7 Showing Figure 4 A view of the cross-section along the section line A - A in; Detailed Description of the Invention

[0044] In the following description of the preferred embodiments, it is to be considered that the disclosure in different aspects is not limited to the details of the construction and arrangement of the components as shown in the subsequent description and the drawings. The embodiments can be implemented or carried out in different ways in practice. Further, it is to be noted that the expressions and terms used herein are for the purpose of description only and should not be construed by those skilled in the art as limiting. In addition, in the following description, the same reference numerals in different embodiments or drawings denote the same or similar features or objects, so that in some cases, a repeated detailed description thereof is not made in order to maintain the compactness and overview of the views.

[0045] Figures 1 to 7 An overview of a lamp socket for a lamp module according to an embodiment of the present invention is shown. The lamp module shown complies with and meets the specifications of the XLS platform (e x changeable L ED s ignal lamp) or UNECE Regulation No. 128. Examples of such lamp modules - but not implementing the invention described herein - can also be found in the following publications: US2019063706A1, DE 102017214659A1, US2019110348A1, DE 102017217883A1, DE102017222649 A1, DE 102018202464 A1, US 2019306939A1, DE 102018201228 A1, DE102017213269 A1, DE 102015206471A1.

[0046] In Figure 1 and Figure 2 a perspective view of the unassembled lamp socket 10 is shown from obliquely above or obliquely below. The arrows shown depict the insertion directions of the connector section 5 with respect to the lamp socket 10 and the receiving section 1, respectively. Generally, the lamp socket 10 can have other parts, but in this embodiment, only the two mentioned sections are involved. First, the two sections are described in detail.

[0047] The receiving section 1 includes an injection molded part 2, a metal body 3, and two first contact pins 41, 42. The receiving section 1 is manufactured by injection molding and encapsulating the metal body 3 and the two first contact pins 41, 42 with a plastic material. The injection molded part 2 is on the end side, i.e., at Figure 1It has a cylindrical section 27 at the top. From the side surface of the cylindrical section, there are sections 21, 22, 23, and 24 protruding in the radial direction. These protruding sections serve as locking or key elements when the LED module to be manufactured is installed in the corresponding receiving part of a headlight (not shown). The cylindrical section 27 internally releases a cylindrical cavity 28 via an annular opening 29. The bottom surface of the cylindrical cavity forms a receiving surface 35 for receiving a substrate or a carrier element for an electronic component. The electronic component can have a driver and a plurality of corresponding LEDs (not shown). The cylindrical section 27 or the cylindrical cavity 28 constitutes a central axis, which is herein referred to as the first axis 100 with respect to the placement and receiving section 1. The receiving surface 35 is perpendicular to the first axis 100 and is provided by the metal body 3. The placed substrate is in large-area contact with the receiving surface 35 and can be connected to it through a thermal paste or a thermal adhesive or a thermal pad to ensure efficient heat transfer from the substrate to the metal body 3. The LEDs are arranged on the substrate and emit in the direction of the first axis 100 when the substrate is installed and the electronic component is powered.

[0048] The injection molded part 2 also has a disk-shaped section 25, which is connected to the cylindrical section 27 in the backward direction (downward in Figure 1 it). The disk-shaped section 25 is especially used to accommodate a sealing ring (not shown), which seals the opening in the receiving part of the headlight in the installed state of the LED module, and the LED module is inserted through the opening.

[0049] The metal body 3 forms a partially encapsulated, coherent body. In Figure 1 it, the described receiving surface 35 and the cooling ribs 33 axially extending in the backward direction are visible. In this embodiment, there are seven cooling ribs 33, which are arranged in a ring around the downward-opening internal space, and the arrangement is interrupted in the radial direction. In the radial direction, the contact wires to be described are deflected by 90° to form a correspondingly oriented connector section 5 (the eighth rib is omitted). As can be seen in Figure 7 it, the cooling ribs are connected to the receiving surface 35 via the same cylindrical section of the metal body 3. Thus, the heat received by the receiving surface 35 can be efficiently transferred to the cooling ribs 33 for further dissipation.

[0050] The placement and receiving section 1 also has two first contact pins 41 and 42. The two first contact pins 41 and 42 extend parallel to the first axis 100, and one end side of them slightly protrudes from the receiving surface 35 through the void 37 in the receiving surface 35 (see Figure 7 ). Here, the corresponding ends are conductively connected to the relevant terminals (positive and negative or ground) after the substrate is installed. As can be seen in Figure 2As can be seen, the opposite ends of the first contact pins 41 and 42 are exposed in the backward direction (upward in Figure 2 ) in the internal space formed by the cooling ribs and are themselves encapsulated or exposed. The contact pins 41 and 42 are provided by straight bent bars and are fixed in their positions by injection molding encapsulation.

[0051] The connector section 5 will be described in detail below with reference to Figure 1 and Figure 2 .

[0052] The connector section 5 is formed as an independent component and has a connecting section 51 and an actual connector 52 as well as two second contact pins 71, 72. The connector section 5 is manufactured in the same way as the placement and accommodation section 1 during the injection molding process, wherein the two second contact pins 71, 72 are encapsulated by injection molding with plastic material. The connecting section 51 is formed substantially square and includes a groove 54 and a through hole 56, both of which are parallel to each other and extend perpendicular to the second axis 200, which is determined by the actual connector 52 (connector direction).

[0053] The two second contact pins 71, 72 are positioned in the connector section 5 by injection molding parallel to each other and parallel to the second axis 200 (see Figure 2 ). The two second contact pins extend from the groove 54 (where the second contact pins are exposed) along the axis 200 spaced apart from each other into the tubular connector cavity 55, where the second contact pins are also exposed. The spacing between the two contact pins 71, 72 is equal to the spacing between the two contact pins 41, 42. A key and guiding element 53 is arranged at the outer surface of the actual connector 52, which also extends along the second axis 200. In addition, a locking element 57 is provided, which can cooperate with a corresponding element of a coupler (not shown) in order to establish a reliable connection to the power supply source.

[0054] In Figure 1 and Figure 2 the indicated plugging is carried out by introducing the bolt 62 shown in Figure 2 of the injection molded part 2 into the through hole 56 of the connector section 5. Since the bolt 62 extends parallel to the first axis 100, the actual connector has thus been achieved with its second axis 200 and the contact pins 71, 72 extending parallel to the second axis at an angle of 90° with respect to the first axis 100. When the bolt 62 is further pushed into the through hole 56, the ends of the first contact pins 41, 42 also enter the groove 54 of the connector section 5. There, the first contact pins come into contact with the free ends of the second contact pins 71, 72 extending perpendicular to them.

[0055] Upon further insertion, the positioning mechanism 61 shown in Figure 2 , which is also part of the injection molded part 2, comes into contact with the surface of the connector section 5. The positioning mechanism 61 is dimensioned to match the groove 54 such that it can be directly inserted into the groove. Thereby, the azimuthal orientation of the connector section 5 with respect to the receiving and accommodating section 1 is now also determined. At the same time, the groove 54 is closed on one side in the manner described.

[0056] In Figure 4 , a view of the assembled lamp socket 10 is visible from below. The substantially straight second contact pins 71, 72 are slightly bent at their ends that are exposed in the groove 54 such that the contact pins 71, 72 or 41, 42, although having equal spacing themselves, slide smoothly over each other during insertion. Furthermore, the length of the bolt 62 is greater than the length of the through hole 56 such that a protruding region 63 of the bolt 62 results. The protruding region is thermally crimped in order to fix the connector section 5 at the receiving and accommodating element 1, as can be best seen in the Figure 7 sectional view.

[0057] In this state, the groove 54 is also open in the backward direction (downward in Figure 7 ) such that the contact sites between the first contact pins 41, 42 and the second contact pins 71, 72 are respectively exposed. In this embodiment, a laser welding process can be carried out from the outside here, which conductively connects the pins 41 and 71 or 42 or 72. Subsequently, in order to protect the resulting contact sites 81, 82, the groove 54 can be filled with potting compound. Alternatively, a cover can be placed on.

[0058] In Figure 3 , a perspective view of the assembled lamp socket is shown. Figure 4 And Figure 5 a perspective view is shown from below ([[]] Figure 4 [[]]) and a sectional view on the plane BB drawn as in Figure 4 Figure 7 is shown from below ([[]] Figure 5 [[]]). The second contact pins 71, 72 are present in this plane. Figure 5 Figure 6 ) and a sectional view on the plane AA drawn as in Figure 6 And Figure 7 is shown from the side ([[]] Figure 6 [[]]) and a sectional view on the plane AA drawn as in Figure 6 Figure 4 is shown from the side ([[]] Figure 4 [[]]) (slightly offset in depth in Figure 4 Figure 4 in order to better show the details) on the plane AA drawn as in Figure 4 Figure 7

[0059] List of reference numerals

[0060] 1 Receiving and accommodating section

[0061] 2 Injection molded part

[0062] 3 Metal body

[0063] 5 Connector section

[0064] 10 Lamp socket

[0065] 21 Protruding section

[0066] 22 Protruding section

[0067] 23 Protruding section

[0068] 24 Protruding section

[0069] 25 Disk-shaped section

[0070] 27 Cylindrical section

[0071] 28 Cylindrical cavity

[0072] 29 Annular opening

[0073] 33 Cooling rib

[0074] 35 Receiving surface (for the substrate of an electronic component)

[0075] 37 Clearance

[0076] 41 First contact pin in injection molded part 2

[0077] 42 First contact pin in injection molded part 2

[0078] 51 Connection section

[0079] 52 Actual connector

[0080] 53 Key and guiding element

[0081] 54 Groove

[0082] 55 Tubular cavity

[0083] 56 Through hole

[0084] 57 Locking element

[0085] 61 Positioning mechanism

[0086] 62 Bolt

[0087] 63 Protruding section (thermocompression joint section)

[0088] 71 Second contact pin in connector section 5

[0089] 72 Second contact pin in connector section 5

[0090] 81 Contact part

[0091] 82 Contact part

[0092] 100 First axis (mounting and receiving section)

[0093] 200 Second axis (connector section)

Claims

1. A lamp socket (10) for a replaceable LED module, comprising: A placement and accommodation section (1) extending along a first axis (100) for placement in a headlamp housing and for accommodating an electronic component including at least one LED; A connector section (5) extending along a second axis (200) for connection to an external coupler capable of providing a power supply source; At least one contact wire, a first end of the contact wire extending along the first axis (100) into the placement and accommodation section (1) to be connectable to the electronic component after installation of the electronic component, and a second end of the contact wire extending along the second axis (200) in the connector section (5) to be connected to a coupler-side contact terminal there in the case of a closed plug connection, such that electrical power is supplied to the electronic component, wherein the first axis (100) and the second axis (200) enclose an angle with each other, characterized in that the at least one contact wire includes a first contact pin (41, 42) and a second contact pin (71, 72) different from the first contact pin (41, 42), wherein the first contact pin (41, 42) forms the first end and the second contact pin (71, 72) forms the second end, and wherein the two contact pins (41, 42; 71, 72) are conductively connected to each other; wherein the connector section (5) has a through hole (56) formed in a corresponding injection molded part and the placement and accommodation section (1) has a corresponding bolt (62) in a corresponding injection molded part that matches the through hole (56), wherein the length of the bolt (62) is greater than the length of the through hole (56) so as to form a portion (63) of the bolt (62) protruding from the through hole (56) in the plugged-together state, and the portion is used to fix the connector section (5) at the placement and accommodation section (1), preferably by thermocompression bonding, adhesion, screwing or riveting.

2. The lamp socket (10) according to claim 1, wherein the angle is 90°.

3. The lamp socket (10) according to claim 1 or 2, wherein the placement and accommodation section (1) and the connector section (5) are configured as separate sections that are configured to be joined together by installation.

4. The lamp socket (10) according to claim 3, wherein the placement and accommodation section (1) includes an injection molded part (2), and the first contact pin (41, 42) is fixed in the injection molded part by injection molding encapsulation; and / or the connector section (5) includes an injection molded part, and the second contact pin (71, 72) is fixed in the injection molded part by injection molding encapsulation.

5. The lamp socket (10) according to claim 4, wherein the two contact pins (41, 42; 71, 72) are each substantially linearly formed.

6. The lamp socket (10) according to claim 5, Two of the contact pins (41, 42; 71, 72) are conductively connected to each other at the contact sites (81, 82), and at least one of the two contact pins (41, 42; 71, 72), preferably both contact pins (41, 42; 71, 72), is bent in the region of the contact sites (81, 82).

7. The lamp socket (10) according to claim 5 or 6, wherein two of the contact pins (41, 42; 71, 72) are conductively connected to each other at the contact sites (81, 82), and the contact sites (81, 82) are exposed in a groove (54) which is formed in the injection-molded part of the plug-in section (5) and is accessible from the outside.

8. The lamp socket (10) according to claim 7, wherein the contact sites (81, 82) or the connection between the two contact pins (41, 42; 71, 72) is formed by laser welding, a soldering process, or applying a conductive adhesive or also by contact pins (71, 72) configured as cut-off contact parts.

9. The lamp socket (10) according to any one of claims 4 to 8, wherein the plug-in section (5) and the mounting and receiving section (1) have mating positioning mechanisms (61) which fit into each other such that when the plug-in section (5) is plugged onto the mounting and receiving section (1) during installation, the contact pins (41, 42; 71, 72) come into contact with each other or there is a small spacing.

10. The lamp socket (10) according to any one of claims 4 to 9, wherein the mounting and receiving section (1) includes, in addition to at least one first contact pin (41, 42) and the injection-molded part (2), a metal body (3) at least partially injection-molded and encapsulated by the injection-molded part (2), the metal body having a flat receiving surface (35) for carrying a substrate of the electronic component at the end side and having a plurality of annularly arranged cooling ribs (33) in opposite directions with respect to the first axis (100), the cooling ribs at least partially surrounding the internal space, and the plug-in section (5) being inserted into the internal space in the direction of the first axis (100) after being mounted on the injection-molded part (2) of the mounting and receiving section (1).

11. The lamp socket (10) according to any one of claims 4 to 10, wherein the mounting and receiving section (1) has a substantially cylindrical section (27) at the end side, the central axis of the cylindrical section coinciding with the first axis (100), and at least one locking and / or key element being formed as a protruding section (21 - 24) on the side surface of the cylindrical section.

12. The lamp socket (10) according to any one of claims 4 to 11, wherein the plug-in section (5) further has: at least one key element (53) which is configured to cooperate with a key element of a mating coupler to be plugged in; and / or at least one locking element (57) which enables a releasable mechanical connection with the coupler to be plugged in.

13. An LED module, comprising: A lamp socket (10) according to any one of claims 1 to 12; and an electronic component comprising at least one LED, the electronic component being received in the receiving and accommodating section of the lamp socket and conductively connected to the first contact pin.

14. The LED module according to claim 13, wherein the LED module is an LED-based signal lamp that meets the technical requirements of UN / ECE Regulation No.

128.

15. A method for manufacturing a lamp socket according to any one of claims 4 to 12, the method comprising: - providing at least one first contact pin and a second contact pin (41, 42; 71，72)； - injection-molding and encapsulating the first contact pin and the second contact pin (41, 42; 71, 72) separately and apart from each other to form corresponding to the receiving and accommodating section (1) and the connector section (5); - plugging the connector section (5) and the receiving and accommodating section (1) together; - laser welding, soldering or bonding the contact portion between the first contact pin and the second contact pin by means of a conductive adhesive, or forming the contact portion by contact pins (71, 72) implemented as cut-type contacts.

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