Modular cut-off shield for headlights

Abstract

The invention relates to a modular cut-off shield for a headlight. A lighting module for a headlight in a vehicle includes: a light source; a lens; and a housing. The housing holds the light source. The housing also holds the lens at a fixed position relative to the light source and holds the lens spaced apart from the light source. The housing includes an outer surface defining a slot. A cutoff shield extends through the slot and into the interior of the housing between the light source and the lens for blocking a portion of the light emitted from the light source.

Description

[0001] Cross - Reference to Related Applications

[0002] This invention patent application claims the benefit of U.S. Provisional Patent Application No. 63 / 613,834, filed on December 22, 2023, the content of which is incorporated herein by reference in its entirety. Technical Field

[0003] The present disclosure generally relates to lighting for motor vehicles. More specifically, the present disclosure relates to headlamps for passenger vehicles, such as sedans and trucks. Background Art

[0004] The headlamp assembly of a vehicle complies with regulations regarding the cut - off pattern in order to illuminate the road ahead of the vehicle while also minimizing interference to the drivers of other vehicles, including oncoming vehicles and vehicles traveling in the same direction in front of and with the same direction as the subject vehicle. Several different headlamp lighting regulations and standards may apply to different jurisdictions. Examples of such regulations and standards include ECE developed by the United Nations Economic Commission for Europe, standards used in the United States and Canada developed by the U.S. Department of Transportation (DOT), CCC certification standards in China, and SAE standards in the United States.

[0005] The headlamp assembly may include one or more lighting modules, each lighting module configured to provide a specific lighting pattern. There is a need for lighting modules with increasingly smaller sizes and various different layout configurations to provide a stylish arrangement that meets both regulatory and manufacturer requirements for light output. Summary of the Invention

[0006] The present disclosure provides a lighting module for a headlamp in a vehicle. The lighting module includes: a light source, a lens, and a housing. The housing holds the light source. The housing also holds the lens in a fixed position relative to the light source and holds the lens spaced apart from the light source. The housing includes an outer surface defining a slot. A cut - off shield extends through the slot and into the interior of the housing between the light source and the lens for blocking a portion of the light emitted from the light source.

[0007] The present disclosure also provides a headlamp assembly for a vehicle. The headlamp assembly includes: an enclosure; a baffle that is inside the enclosure and defines an opening; and at least one lighting module disposed inside the enclosure. The at least one lighting module includes: a light source; a lens that protrudes through the opening in the baffle; a housing; and a cut - off shield. The housing holds the light source. The housing also holds the lens in a fixed position relative to the light source and holds the lens spaced apart from the light source. The housing includes an outer surface defining a slot. A cut - off shield extends through the slot and into the interior of the housing between the light source and the lens for blocking a portion of the light emitted from the light source.

[0008] These aspects and other aspects of the present disclosure are disclosed in the following detailed description of the embodiments, the appended claims, and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Further details, features, and advantages of the design of the present invention emerge from the following description of exemplary embodiments with reference to the related drawings.

[0010] Figure 1 A schematic block diagram of a vehicle having two headlight assemblies in accordance with the present disclosure is shown;

[0011] Figure 2 A perspective view of three lighting modules arranged in a headlight assembly in accordance with the present disclosure is shown.

[0012] Figures 3A to 3D Four different cut-off shields for use in a given one of the lighting modules to produce different cut-off patterns in accordance with the present disclosure are shown.

[0013] Figure 4 An exploded view of a first lighting module of three lighting modules in accordance with the present disclosure is shown.

[0014] Figure 5 Shown in accordance with the present disclosure Figure 4 A perspective view of the first lighting module in an inverted orientation to show its lower surface.

[0015] Figure 6 An exploded view of a second lighting module of three lighting modules in accordance with the present disclosure is shown.

[0016] Figure 7 An exploded view of a third lighting module of three lighting modules in accordance with the present disclosure is shown.

[0017] Figure 8 Shown in accordance with the present disclosure Figure 7 A perspective view of the third lighting module. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0018] With reference to the drawings, the present invention will be described in detail in view of the following embodiments.

[0019] Figure 1FIG. 0 shows a schematic block diagram of a vehicle 10 having an illumination system 12 according to one aspect of the present disclosure. The vehicle 10 may be a motor vehicle, such as a passenger car or a truck. However, the headlamp assemblies of the present disclosure may be adapted for other types of vehicles such as commercial trucks, buses, trains, etc. The vehicle 10 having the illumination system 12 of the present disclosure may also be referred to as the present vehicle or the host vehicle. The illumination system 12 includes a left headlamp assembly 20a and a right headlamp assembly 20b. Each of the headlamp assemblies 20a, 20b may be similar or identical to each other. In some embodiments, the headlamp assemblies 20a, 20b may include similar internal components or identical internal components and different external components, such as enclosures 22 configured to fit within structures on the corresponding sides of the vehicle 10.

[0020] As Figure 1 shown in FIG. 5, each of the headlamp assemblies 20a, 20b further includes a window 24 of transparent material for emitting light and a baffle 26 disposed within a corresponding one of the enclosures 22. Each of the baffles 26 defines a plurality of openings 28.

[0021] Each of the headlamp assemblies 20a, 20b further includes three illumination modules 30a, 30b, 30c. The three illumination modules 30a, 30b, 30c include a first illumination module 30a, a second illumination module 30b, and a third illumination module 30c, and each of them provides a corresponding beam pattern. The first illumination module 30a, which may be referred to as an LB point module, provides a near-beam point beam pattern with a relatively high intensity over a relatively small illumination angular field. The second illumination module 30b, which may be referred to as an LB extended module, provides a near-beam extended beam pattern with a relatively low intensity and over a relatively large illumination angular field. The third illumination module 30c, which may be referred to as a high-beam module, provides high-intensity illumination over another illumination field that may extend over the near-beam illumination field. However, the principles of the present disclosure may be applied to other headlamp assemblies including fewer or more than three illumination modules and / or illumination modules with different purposes or arrangements.

[0022] In some embodiments, and as described in the present disclosure, each of the three illumination modules 30a, 30b, 30c includes a light source 34 configured to generate light. The light source 34 may include one or more light-emitting diodes (LEDs) disposed on a substrate, such as a printed circuit board. However, the light source 34 may include other types of illumination sources such as LED arrays, organic light-emitting diodes (OLEDs), halogen bulbs, high-intensity discharge (HID) lamps, lasers, etc.

[0023] Each of the three lighting modules 30a, 30b, 30c also includes a secondary lens 36 for focusing and directing the light emitted by the corresponding light source 34. The secondary lens 36 can be made of poly(methyl methacrylate) (PMMA). However, the secondary lens 36 can include one or more other materials. In some embodiments, and as Figure 1 shown, the secondary lenses 36 can each project through a corresponding one of the openings 28 in the baffle 26. Each of the three lighting modules 30a, 30b, 30c also includes a housing 32. The housing 32 can be made of a high-temperature polycarbonate (PC-HT) material. However, the housing can include one or more other materials. The housings 32 each hold the corresponding light source 34 and the corresponding secondary lens 36, where the secondary lens 36 is in a fixed position relative to and spaced apart from the light source 34.

[0024] Figure 2 A perspective view shows the three lighting modules 30a, 30b, 30c in an in-line arrangement as they can be arranged in the headlamp assemblies 20a, 20b. However, the lighting modules 30a, 30b, 30c can be arranged in a vertically stacked configuration or any other arrangement. When viewed from the front, each of the three lighting modules 30a, 30b, 30c has a generally rectangular secondary lens 36. The secondary lens 36 can have a relatively thin profile. For example, in some embodiments, the secondary lenses 36 can each have a height of about 15 mm and a width of about 45 mm. Lighting modules with such small dimensions can pose challenges for packaging and assembly, which can be particularly difficult in cases including a cut-off shield and associated structures for positioning and attaching the cut-off shield 50 to the housing 32.

[0025] Also as Figure 2 shown, each of the housings 32 includes a number of outer surfaces 44, 45, which include an upper surface 44 and a lower surface 45. The upper surface 44 of the third lighting module 30c defines a slot 46, and the cut-off shield 50 extends through the slot 46 and into the interior of the housing 32 between the light source 34 and the secondary lens 36 for blocking a portion of the light emitted from the light source 34. Thus, the cut-off shield 50 can serve as a high-contrast edge defining a high beam pattern. In some embodiments, the lower surfaces 45 of the first lighting module 30a and the second lighting module 30b each also include a slot 46 for receiving the corresponding cut-off shield 50.

[0026] The cutoff shield 50 of the present disclosure mounted outside the housing 32 provides several advantages over alternative designs. The combination of the slots 46 that receive the cutoff shield 50 allows the lighting modules 30a, 30b, 30c to be easily manufactured without any fasteners or other structures inside the housing 32 that might otherwise interfere with the installation of the secondary lens 36 and might otherwise block a portion of the light passing through the secondary lens 36. The combination of the slots 46 that receive the cutoff shield 50 allows the lighting modules 30a, 30b, 30c to be relatively easily manufactured with a thin profile to meet manufacturer requirements.

[0027] The secondary lens 36 can be used to transform the lighting pattern from each of the three lighting modules 30a, 30b, 30c. The first lighting module 30a and the second lighting module 30b are each configured to produce a near-beam lighting pattern of illumination below the corresponding cutoff line, and the third lighting module 30c is configured to produce a far-beam lighting pattern of illumination above the corresponding cutoff line. Due to the transformation function of the secondary lens 36, the cutoff shields 50 of the first lighting module 30a and the second lighting module 30b can each be mounted through the respective lower surface 45 and extend upward into the interior of a corresponding one of the housings 32 to produce a corresponding near-beam lighting pattern with a lighting pattern below the corresponding cutoff line. However, the cutoff shield 50 of the third lighting module 30c can be mounted through the upper surface 44 and extend downward into the interior of the housing 32 to produce a far-beam lighting pattern of illumination above the corresponding cutoff line.

[0028] Each housing in the housing 32 has a tubular shape with a generally rectangular cross-section and extends between a first end 40 and a second end 42. The secondary lenses 36 are each disposed within a corresponding one of the housings 32 and adjacent to the first end 40. The light source 34 is attached to each housing in the housing 32 and adjacent to the second end 42. In some embodiments, and as Figure 2 shown, the housing 32 includes a mounting flange at the second end 42 for mounting the housing 32 within the corresponding headlight assemblies 20a, 20b.

[0029] In some embodiments, the tubular shape of each housing in the housing 32 defines an interior with a substantially constant cross-section over substantially the entire length between the first end 40 and the second end 42. Alternatively or additionally, the tubular shape of one or more of the housings 32 can define a tapered portion that tapers in width and / or height from the second end 42 toward the first end. This substantially constant cross-section or tapered portion can allow the secondary lens 36 to slide into place through an opening at the second end 42 and be fastened within the housing 32 adjacent to the first end 40.

[0030] In some cases, such as Figure 2 in the third illumination module 30c shown in Figure 2 , the upper surface 44 and the lower surface 45 are each flat. In other cases, one or both of the upper surface 44 and / or the lower surface 45 may be non-flat. For example, Figure 2 each of the first illumination module 30a and the second illumination module 30b shown in Figure 2 includes such an upper surface 44 that has a ridge protruding from the upper surface 44 along the length between the first end 40 and the second end 42. However, the upper surface 44 and / or the lower surface 45 may have different flat or non-flat shapes, such as one or more simple or complex curved surfaces or different tapers.

[0031] In some embodiments, the cutoff shield 50 is attached to the outer surfaces 44, 45 of the housing 32 without any fasteners for holding the cutoff shield 50 inside the housing 32. For example, the outer surfaces 44, 45 of the housing 32 may define one or more fixing features adjacent to the groove 46, and the fixing features are deformed to fix the cutoff shield 50 to the outer surface of the housing 32. Figure 2 The housing 32 of the third illumination module 30c is shown, and the housing 32 has fixing features in the form of two fixing pins 52 adjacent to the groove 46 defined in the upper surface 44 of the housing 32. Each of the two fixing pins 52 extends through a corresponding hole in the cutoff shield 50 and is configured to melt or otherwise deform to fix the cutoff shield 50 to the upper surface 44 of the housing 32. The fixing pins 52 may be integrally formed with the housing, such as integrally formed as a single molded article. One or more of the fixing features may include other structures, such as clips, tabs, snaps, or fasteners, that can be partially or entirely formed by the housing.

[0032] In some embodiments, the outer surfaces 44, 45 of the housing 32 define alignment features adjacent to the groove 46, and the alignment features engage corresponding structures of the cutoff shield 50 for aligning the cutoff shield 50 relative to the secondary lens 36 and the light source 34 at a specific position. For example, Figure 2 The housing 32 of the third illumination module 30c is shown, and the housing 32 has alignment features in the form of two alignment pins 54 adjacent to the groove 46 defined in the upper surface 44 of the housing 32. Each of the two alignment pins 54 extends through a corresponding hole in the cutoff shield 50 for aligning the cutoff shield 50 relative to the secondary lens 36 and the light source 34 at a specific position. The alignment pins 54 may be integrally formed with the housing, such as integrally formed as a single molded article. One or more of the alignment features may include other structures, such as tabs, grooves, notches, or holes, and the other structures may be partially or entirely formed by the housing.

[0033] Figures 3A to 3D Each shows a different cut-off shield among the cut-off shields 50a, 50b, 50c, 50d, and these cut-off shields can each be used as the cut-off shield 50 in a given one of the lighting modules 30a, 30b, 30c, 30d to produce different cut-off patterns. Figure 3A Shows a first cut-off shield 50a that can also be referred to as a high beam cut-off shield, and the first cut-off shield 50a defines a first end edge 72a, and the first end edge 72a is configured to produce a cut-off pattern as a flat horizontal line. Figure 3B Shows a second cut-off shield 50b that can also be referred to as an SAE cut-off shield, and the second cut-off shield 50b defines a second end edge 72b, and the second end edge 72b is configured to produce a cut-off pattern according to the Society of Automotive Engineers (SAE) standards in North America. Figure 3C Shows a third cut-off shield 50c that can also be referred to as an ECE-LHD cut-off shield, and the third cut-off shield 50c defines a third end edge 72c, and the third end edge 72c is configured to produce a cut-off pattern according to the United Nations Economic Commission for Europe (ECE) standards for Europe and a left-hand drive (LHD) configuration. Figure 3D Shows a fourth cut-off shield 50d that can also be referred to as an ECE-RHD cut-off shield, and the fourth cut-off shield 50d defines a fourth end edge 72d, and the fourth end edge 72d is configured to produce a cut-off pattern according to the ECE standards and a right-hand drive (RHD) configuration.

[0034] The different configurations of the cut-off shield 50 can allow for the common design of one or more of the three lighting modules 30a, 30b, 30c and have shared components, and the different configurations of the cut-off shield 50 can be customized for different regions with minimal modification and rework costs, thereby providing several cost-saving opportunities for alternative designs in specific regions. The different configurations of the cut-off shield 50 of the present disclosure can also provide an enhanced ability to modify the cut-off pattern for future regulatory and / or manufacturer requirements by only changing the cut-off shield 50 without having to change other components of the lighting modules 30a, 30b, 30c, thereby providing additional flexibility and cost-saving opportunities.

[0035] Some or all of the different cut-off shields 50 can be made of a flat sheet of material, such as a metal sheet, and the flat sheet of material has one or more bends to define a cross-section in an L-shaped shape along a part or all of the width of the cut-off shield. The cut-off shield 50 can be made of, for example, stainless steel. However, the cut-off shield 50 can include other materials. In some embodiments, and asFigures 3A to 3D As shown in, the cutoff shield 50 includes a shield portion 70 and a base portion 74 that is perpendicular to the shield portion 70. Each of the shield portions in the shield portion 70 defines a corresponding one of the end edges 72a, 72b, 72c, 72d that is opposite to the base portion 74, and is configured to extend through the slot 46 and enter the interior of the housing 32 between the light source 34 and the secondary lens 36 to block a portion of the light emitted from the light source 34. In some embodiments, and as Figures 3A to 3D shown in, each of the base portions 74 defines a plurality of holes 76 for receiving a corresponding one of the fixing pins 52 and / or a corresponding one of the alignment pins 54.

[0036] In some embodiments, the shield portion 70 includes two or more panels 70a, 70b that extend parallel to each other and are spaced apart from each other. For example, the second cutoff shield 50b includes a first panel 70a and a second panel 70b, and the second panel 70b is parallel to and spaced apart from the first panel 70a such that the two panels 70a, 70b are at different distances from the light source 34a. The two panels 70a, 70b together define the second end edge 72b.

[0037] In some embodiments, and in the case where the outer surfaces 44, 45 of the housing 32 are not flat, the base portion 74 may include two or more different sections 74a, 74b, 74c that are at different heights in a direction transverse to the shield portion to engage the corresponding portions of the outer surfaces 44, 45 so as to be fixed to the outer surfaces 44, 45. For example, Figures 3B to 3D each of the cutoff shields 50 shown in each of the figures in includes a base portion 74 having three different sections 74a, 74b, 74c, and each section 74a, 74b, 74c is configured to engage the lower surface 45 having a ridge, as Figure 5 best shown in.

[0038] Figures 4 to 5Each shows an exploded view of the first lighting module 30a. As shown, the first lighting module 30a includes a housing 32, wherein a light source 34 and a secondary lens 36 are each configured to be attached to the housing 32. As shown, the light source 34 includes a substrate 60, such as a printed circuit board (PCB), wherein five LEDs 62 are arranged in a horizontal line on the substrate 60. A heat sink 64 is attached to the rear surface of the substrate 60 opposite the LEDs 62. A set of first screws 65 extends through the substrate 60 for securing the heat sink 64 to the substrate 60. A first main lens 68a is disposed opposite the LEDs 62, between the LEDs 62 and the secondary lens 36. The first main lens 68a may be made of polymethacrylimide (PMMI). However, the first main lens 68a may include one or more other materials. A set of four second screws 66 extends through the heat sink 64 and the substrate 60 for securing the light source to the second end 42 of the housing 32.

[0039] Figure 6 shows an exploded view of the second lighting module 30b, which is similar to Figures 4 to 5 the first lighting module 30a shown in, except having only three LEDs 62 and having a second main lens 68b in place of the first main lens 68a. The second main lens 68b may be similar or identical to the first main lens 68a, except that the second main lens 68b is configured to project light from the three LEDs 62 and provide an extended beam pattern over a larger illumination angular field. The second lighting module 30b also includes a fifth cutoff shield 50e defining a fifth end edge 72e, the fifth end edge 72e being configured to produce a corresponding cutoff pattern as a flat horizontal line and cause the extended beam illumination pattern to have an illumination field extending up to a corresponding cutoff line.

[0040] Figures 7 to 8 Each shows different views of the third lighting module 30c. Figure 7 shows an upper surface 44 defining a step 48 adjacent to the slot 46. The step 48 provides a flat surface parallel to the central axis of the housing 32 for engaging and positioning the base portion 74 of the cutoff shield 50. A fixing pin 52 and an alignment pin 54 each project from the step 48 and are transverse to the step 48.

[0041] The foregoing description is not intended to be exhaustive or to limit the disclosure. The individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but rather, even if not specifically shown or described, the individual elements or features of a particular embodiment are interchangeable and may be used in a selected embodiment where applicable. The individual elements or features of a particular embodiment may also vary in many ways. Such variations should not be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. A lighting module (30a, 30b, 30c) for a headlight in a vehicle (10), the lighting module comprising: Light source (34); Lens (36); a housing (32) that holds the light source (34) and holds the lens (36) in a fixed position relative to the light source (34) and holds the lens (36) spaced apart from the light source (34), wherein the housing (32) includes an outer surface (44, 45) defining a groove (46); as well as A cut-off shield (50) extends through the slot (46) and into the interior of the housing (32) between the light source (34) and the lens (36) for blocking a portion of the light emitted from the light source (34).

2. The lighting module (30a, 30b, 30c) according to claim 1, wherein: The cut-off shield (50) is fixed to the outer surface (44, 45) of the housing (32).

3. The lighting module (30a, 30b, 30c) according to claim 2, wherein: The outer surface (44, 45) of the housing (32) defines a securing feature (52) adjacent the slot (46) and the securing feature (52) deforms to secure the cutoff shield (50) to the outer surface (44, 45) of the housing (32).

4. The lighting module (30a, 30b, 30c) according to claim 2, wherein: The outer surface (44, 45) of the housing (32) defines an alignment feature (54) adjacent the slot (46), and the alignment feature engages a corresponding structure of the cutoff shield (50) for aligning the cutoff shield (50) at a specific position relative to the lens (36) and the light source (34).

5. The lighting module (30a, 30b, 30c) according to claim 1, wherein: The outer surface (44, 45) is an upper surface (44) configured to face upward when the lighting module (30a, 30b, 30c) is in an installed orientation in the vehicle (10).

6. The lighting module (30a, 30b, 30c) according to claim 1, wherein: The outer surface (44, 45) is a lower surface (45) configured to face downward when the lighting module (30a, 30b, 30c) is in an installed orientation in the vehicle (10).

7. The lighting module (30a, 30b, 30c) according to claim 1, wherein: The cut-off shield (50) is one of a plurality of different cut-off shields (50), each of the plurality of different cut-off shields (50) having a different shape to define a different cut-off pattern.

8. The lighting module (30a, 30b, 30c) according to claim 1, wherein: The stop shield (50) comprises a flat sheet of material having a bend to define an L-shaped cross-section along the width of the stop shield.

9. The lighting module (30a, 30b, 30c) according to claim 1, wherein: The shutoff shield (50) is attached to the outer surface (44, 45) of the housing (32) without requiring any fasteners within the interior of the housing (32) for retaining the shutoff shield (50).

10. The lighting module (30a, 30b, 30c) according to claim 1, wherein: The outer surfaces (44, 45) are non-planar, wherein the cut-off shield (50) comprises a shield portion (70) extending through the slot (46) and a base portion (74) for fixing to the outer surface (44, 45) of the housing (32), and wherein the base portion (74) defines two or more distinct sections (74a, 74b, 74c), wherein each of the two or more distinct sections (74a, 74b, 74c) is configured to engage a corresponding portion of the outer surface (44, 45) for securing to the outer surface (44, 45).

11. The lighting module (30a, 30b, 30c) according to claim 10, wherein: The two or more different sections (74a, 74b, 74c) have different heights in a direction transverse to the shield portion (70).

12. The lighting module (30a, 30b, 30c) according to claim 10, wherein: The shutoff shield (50) includes a shield portion (70) extending through the slot (46), and wherein the shield portion (70) includes two panels (70a, 70b) extending parallel to each other and spaced apart from each other.

13. A headlight assembly for a vehicle (10), the headlight assembly comprising: Enclosure (22); a baffle (26) located within the enclosure (22) and defining an opening (28); as well as At least one lighting module (30a, 30b, 30c), the at least one lighting module (30a, 30b, 30c) being arranged inside the enclosure (22) and comprising: Light source (34); a lens (36) protruding through the opening in the baffle (26); a housing (32) that holds the light source (34) and holds the lens (36) in a fixed position relative to the light source (34) and holds the lens (36) spaced from the light source (34), wherein the housing (32) includes an outer surface (44, 45) defining a groove (46); and A cut-off shield (50) extends through the slot (46) and into the interior of the housing (32) between the light source (34) and the lens (36) for blocking a portion of the light emitted from the light source (34).

14. The headlamp assembly according to claim 13, wherein: The cut-off shield (50) is fixed to the outer surface (44, 45) of the housing (32).

15. The lighting module (30a, 30b, 30c) according to claim 14, wherein: The outer surface (44, 45) of the housing (32) defines a securing feature (52) adjacent the slot (46) and the securing feature (52) deforms to secure the cutoff shield (50) to the outer surface (44, 45) of the housing (32).

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