Light module, method for manufacturing a light module, and rear view device

Abstract

A light module (10) comprising: a lens unit (40) formed with a bottom (42), a cover (44), and one or more side walls, where the one or more side walls provide one or more insertion openings (49); a printed circuit board unit (30) carrying one or more light sources and inserted into the lens unit through a first one of the one or more insertion openings such that light emitted by the one or more light sources exits the lamp module through the bottom and / or cover of the lens unit; and a housing unit (50) having a bottom opening (52), a cover opening (54) and one or more side walls wherein the lens unit is arranged within the housing unit such that the bottom opening and the cover opening of the housing unit are respectively closed by the bottom and the cover of the lens unit, and the one or more insertion openings of the lens unit are closed by the one or more side walls of the housing unit. The invention also relates to an external rearview device with such a lamp module.

Description

[0001] This application is a divisional application of Chinese Patent Application No. 202210303987.9, with the invention title "Lamp Module, Method for Manufacturing a Lamp Module, and Rear View Device", and the filing date of March 25, 2022. Technical Field

[0002] The present invention relates to a lamp module, in particular a lamp module suitable for an external rear view device, and to an external rear view device for a vehicle having such a lamp module. Background Art

[0003] US 2005 / 0168922 A1 relates to a lamp module in the form of an optoelectronic component based on surface mounting technology, the optoelectronic component including a conductive material, an opaque plastic material, and a chamber, wherein the conductive material serves as the base of the assembly, the opaque plastic material provides a housing for the entire component, the chamber is located within the plastic material, and an optoelectronic chip is mounted in the chamber. The known lamp module provides a solderless LED holder without additional measures for attachment to a device.

[0004] EP 3 138 734 B1 discloses a lamp assembly for an external rear view device, which includes at least one lamp module for the lamp assembly and at least one printed circuit board unit, wherein the lamp module includes: a light source unit having at least one wire for electrical connection to the printed circuit board unit of the lamp assembly, wherein the light source unit includes an illumination surface and a light source housing; a housing unit that supports the light source unit and is provided with connection and / or holding means for attachment to at least a part of the rear view device, in particular a housing part; and a sealing means for waterproofing and dustproofing the connection between the lamp module and the at least a part. The printed circuit board unit is remote from the lamp module, and the wire (or wires) of the lamp module is soldered to the printed circuit board unit providing a pad pattern. The sealing means forms the outer periphery of the housing unit in the region supporting the light source unit, and the housing unit is formed together with the light source housing and the sealing means by 2-K injection molding. Summary of the Invention

[0005] It is an object of the present invention to provide a lamp assembly that is not only compact and easy to install, but also easy to manufacture and at least weatherproof, preferably waterproof.

[0006] This object is achieved by a lamp module, which includes: a lens unit, which is formed with a bottom, a cover portion, and one or more side walls located between the bottom and the cover portion, wherein the one or more side walls provide one or more insertion openings; a printed circuit board unit, which carries one or more light sources and is inserted into the lens unit through a first insertion opening among the one or more insertion openings, such that the light emitted by the one or more light sources exits the lamp module through the bottom and / or the cover portion of the lens unit; and a housing unit, which is provided with a bottom opening, a cover opening, and one or more side walls located between the bottom opening and the cover opening, wherein the lens unit is arranged inside the housing unit, such that the bottom opening of the housing unit is closed by the bottom of the lens unit, the cover opening of the housing unit is closed by the cover portion of the lens unit, and the one or more insertion openings of the lens unit are closed by the one or more side walls of the housing unit.

[0007] It is proposed that the printed circuit board unit is supported by the lens unit, wherein preferably, two opposite edges of the printed circuit board unit are arranged on or in two guide rails provided by the lens unit, particularly by two opposite side walls of the lens unit.

[0008] The embodiment can be further specified as: the printed circuit board unit provides one or more connector pins and / or at least one extension portion, wherein preferably, the one or more connector pins extend into a second insertion opening among the one or more insertion openings of the lens unit, and / or the at least one extension portion extends into a third insertion opening among the one or more insertion openings of the lens unit, wherein in particular, the second and / or third insertion openings are provided by the first insertion opening.

[0009] Furthermore, the features of the embodiment can lie in that: the housing unit is provided with at least one stopping and / or aligning feature for the lens unit and / or the printed circuit board unit, wherein preferably, the housing unit provides a first stepped extension for positioning the bottom of the lens unit around its bottom opening, and / or a second stepped extension for positioning the cover portion of the lens unit around its cover opening, and / or an internal step on the inner surface of the side wall closing the first insertion opening of the lens unit for positioning the at least one extension portion of the printed circuit board unit.

[0010] The present disclosure also proposes that a first welding trace is provided between the housing unit and the lens unit, the first welding trace preferably surrounds the bottom opening of the housing unit, and in particular, the first welding trace is defined by a pointed portion extending parallel to the first stepped extension; and / or a second welding trace is provided between the housing unit and the lens unit, the second welding trace preferably surrounds the cover opening of the housing unit, and in particular, the second welding trace is defined by a pointed portion extending along the second stepped extension.

[0011] The first and second welding traces can be implemented simultaneously.

[0012] It is proposed that at least one connector extension is provided by the housing unit for inserting a connector for connecting a printed circuit board unit, wherein preferably, the at least one connector extension is provided by the side wall of the one or more insertion openings enclosing the lens unit, in particular on the outer surface of the side wall formed in the region of the inner step portion; and / or wherein preferably, a spacer extends in the at least one connector extension, in particular between two connector pins of the one or more connector pins of the printed circuit board unit.

[0013] In addition, the one or more light sources may include at least two, preferably three light source units, wherein preferably each light source unit includes an LED unit.

[0014] The lens unit may be formed of a transparent and / or light-transmissive plastic material, and / or the housing unit may be formed of an opaque and / or light-impermeable plastic material.

[0015] It is further proposed that the housing unit is provided with, in particular formed with, an attachment portion, wherein preferably the attachment portion is adapted to mount the lamp unit to the rearview device by means of a clip, snap, and / or latch connection, and / or wherein preferably the attachment portion is provided with an attachment extension, and / or wherein preferably the attachment portion has a T-shaped cross-section.

[0016] The present invention also provides an external rearview device having at least one rearview element disposed in a head assembly and at least one lamp unit of the present disclosure for providing a side turn indicator, blind spot detection, a marker lamp, a door handle lamp, and / or a proximity lamp.

[0017] It is also proposed that the illumination surface of the lamp module (preferably provided by the bottom of the lens unit) is flush with the outer surface of the external rearview device.

[0018] An embodiment of the external rearview device of the present disclosure may further include a base assembly for attachment to a vehicle, wherein the head assembly is movable relative to the base assembly.

[0019] It is also proposed that at least one first lamp module is attached to the head assembly, in particular the head frame, and / or at least one second lamp module is attached to the base assembly, wherein preferably the attachment portion of the lamp module provides a releasable clip, snap, and / or latch connection.

[0020] Finally, it is proposed that a connector enters each connector extension of the lamp module to seal it. Description of the Drawings

[0021] When read in conjunction with the accompanying drawings, the foregoing summary and the following detailed description will be better understood. For the purpose of illustration, certain examples of the present disclosure are shown in the drawings. It should be understood, however, that the present disclosure is not limited to the precise arrangements and instrumentalities shown. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of systems, devices, and methods consistent with the present disclosure and, together with the detailed description, serve to explain the advantages and principles consistent with the present disclosure, in which:

[0022] Figure 1a is a perspective view of a lens unit of a lamp module of the present disclosure;

[0023] Figure 1b is Figure 1a another perspective view of the lens unit of;

[0024] Figure 2 is a top view of a housing unit of the lamp module of the present invention;

[0025] Figure 3 is a longitudinal section of the lamp module of the present invention;

[0026] Figure 4 is Figure 3 a perspective view of the lamp module of, with a connector;

[0027] Figure 5 is of the lamp module mounted to a head frame of a rearview device Figure 4 a perspective view;

[0028] Figure 6a is Figure 2 a transverse section of the housing unit of;

[0029] Figure 6b is a section taken along line B-B of Figure 6a ;

[0030] Figure 6c is Figure 6b an enlarged detail view of the lower end in; and

[0031] Figure 6d is Figure 6b an enlarged view of the upper end of. DETAILED DESCRIPTION

[0032] The lamp module 10 of the present disclosure is as shown in Figure 3 and Figure 4 . Accordingly, the lamp module 10 includes an opaque plastic housing unit 50 as shown in Figure 2 and a lens unit 40 made of a completely transparent material, particularly a completely transparent plastic, which lens unit 40 houses and bears a printed circuit board unit 30 carrying three LED units 20, 21, 22, as shown in Figure 1a and Figure 1b . Accordingly,Figure 3 shows a Figure 2 lens unit 40 disposed within a Figure 1a housing unit 50 and a 1b lens unit 40.

[0033] The lens unit 40 includes a bottom 42 which serves as a light window for light emitted by one or two of the LED units 20, 21, 22. Opposite the bottom 42 is a cover portion 44, and there is at least one side wall between the bottom 42 and the cover portion 44. Below the cover portion 44, a printed circuit board unit 30 with the LED units 20, 21, 22 is inserted by bringing opposite edges of the printed circuit board unit 30 into two guide rails 46, 48 provided by the lens unit 40. To allow the printed circuit board unit 30 with the LED units 20, 21, 22 to be inserted into the lens unit 40 in this way, the lens unit 40 is provided with at least one insertion opening 49 which is located between the bottom 42 and the cover portion 44 of the lens unit and is thus provided by the at least one side wall, as Figure 3 clearly shown. For example, the lens unit 40 may be formed with five three side walls between the bottom 42 and the cover portion 44.

[0034] The housing unit 50 is formed with a connector extension 51 which will be described below. In addition, the housing unit 50 is formed with a bottom opening 52, a cover opening 54, and at least one side wall therebetween. As soon as the lens unit 40 is inserted into the housing unit 50, these two openings 52, 54 are closed. Specifically, the bottom 42 of the lens unit 40 closes the bottom opening 52 of the housing unit 50, while the cover portion 44 of the lens unit 40 closes the cover opening 54 of the housing unit 50, as Figure 3 shown. Still further, the insertion opening 49 of the lens unit 40 is closed by the housing unit 50, for example by a side wall of the housing unit 50 provided with the connector extension 51.

[0035] To provide a sealed lamp module 10, the lens unit 40 and the housing unit 50 are interconnected by two separate welding traces, as Figure 2 indicated by two welding traces 56, 58 in Figure 3 and by welding areas 56a, 56b, 58a and 58b in

[0036] Accordingly, no additional O - ring seals are required. Figure 5 In addition, when the lamp module 10 is mounted to a rear - view device, particularly its head frame 200 as Figure 4As shown. The connector 100 is not only used for the electrical connection of two connector pins 32, 34 extending from the printed circuit board unit 30 and thus for the electrical connection of the printed circuit board unit 30 to a control unit and / or a power supply (not shown) via the cables 110, 120, but also provides a final seal for the lamp module 10 such that all housing apertures are closed. In fact, the connector 100 closes both the opening in the housing unit 50 in the region of the connector extension 51 and the insertion opening 49 in the region of the two connector pins 32, 34.

[0037] In addition to the two connector pins 32, 34, the printed circuit board unit 30 is provided with an attachment extension 36, see Figure 1a , Figure 1b and Figure 3 . The attachment extension 36 and the two connector pins 32, 34 extend in the direction of the insertion opening 49, and the attachment extension 36 engages an internal step 59 of the housing unit 50 that extends into the interior of the housing unit 50. Thus, the attachment extension 36 and the step 59 ensure the correct positioning of the subassembly consisting of the lens unit 40 and the printed circuit board unit 30 carrying the LED units 20, 21, 22 in the housing unit 50.

[0038] The housing 50 is also provided with an attachment part 60, which can be clearly seen in Figure 4 and Figure 5 . The attachment part is provided with an attachment extension 61 such that its cross-section is generally T-shaped. The attachment part 60 is suitable for clip-connecting the lamp module 10 to the head frame 200.

[0039] Details of the seal provided by two separate welding traces 56, 58 with welding areas 56a, 56b, 58a, 58b are further shown in Figures 6a to 6d .

[0040] Figure 6a A cross-section of the housing unit 50 is shown, Figure 6b showing a cross-section taken along line B-B in Figure 6a which passes through the two welding traces 56, 58. Details of the bottom welding trace area 56b are shown in Figure 6d , and details of the top welding trace area 56b are shown in Figure 6c .

[0041] Thus, the edges provided around the openings 52 and 54 of the housing unit 50 are shaped to support the bottom 42 and the cover part 44 of the lens unit 40 respectively, and are conducive to welding for sealing the unit 10. For this purpose, stepped extensions 56ba and 58ba are provided to surround the edges of the bottom 42 and the cover part 44 respectively. Additionally, in Figure 6d and Figure 6cThe pointed portions 56bb and 58bb that provide the welding traces 56, 58 can be seen to extend parallel to the corresponding stepped extensions 56ba or on the stepped extensions 58ba.

[0042] Once installed in the rearview device and connected to the connector 100 inserted into the connector extension 51, the final lamp unit 10 becomes a sealed module, where the transparent lens 40 allows the LED light to pass through the bottom 42 of the lens and the bottom opening 54 of the housing unit 50, thus complying with the EC48 regulations.

[0043] Those skilled in the art will understand that the above embodiments can be changed without departing from the broad inventive concept of the above embodiments. Therefore, it should be understood that the invention disclosed herein is not limited to the specific embodiments disclosed, but is intended to cover modifications within the spirit and scope of the present invention.

[0044] Reference numerals

[0045] 10 Lamp module

[0046] 20 LED unit

[0047] 21 LED unit

[0048] 22 LED unit

[0049] 30 Printed circuit board unit

[0050] 32 Connector pin

[0051] 34 Connector pin

[0052] 36 Extension

[0053] 40 Lens unit

[0054] 42 Bottom

[0055] 44 Cover part

[0056] 46 Guide rail

[0057] 48 Guide rail

[0058] 49 Insertion opening

[0059] 50 Housing unit

[0060] 51 Connector extension

[0061] 52 Bottom opening

[0062] 54 Cover part opening

[0063] 56 Welding trace

[0064] 56a, 56b Welding area

[0065] 56ba stepped extension

[0066] 56bb pointed portion

[0067] 58 welding trace

[0068] 58a, 58b welding area

[0069] 58ba stepped extension

[0070] 58bb pointed portion

[0071] 59 internal step

[0072] 60 attachment element

[0073] 61 attachment extension

[0074] 100 connector

[0075] 110 cable

[0076] 110 cable

[0077] 200 head frame

Claims

1. A method for manufacturing a lamp unit (1), comprising the following steps: • Providing a lens unit (40) having a bottom (42), a cover part (44), and one or more side walls located between the bottom (42) and the cover part (44), wherein the one or more side walls provide one or more insertion openings (49); • Providing a printed circuit board unit (30) carrying one or more light sources; • Inserting the printed circuit board unit (30) into the lens unit (40) through a first insertion opening (49) among the one or more insertion openings (49), such that light emitted by the one or more light sources passes through the bottom (42) and / or the cover part (44) of the lens unit (40) and exits the lamp module (1); • Providing a housing unit (50) having a bottom opening (52), a cover part opening (54), and one or more side walls located between the bottom opening (51) and the cover part opening (53); and • Arranging the lens unit (40) within the housing unit (50) such that the bottom opening (52) of the housing unit (50) is closed by the bottom (42) of the lens unit (40), the cover part opening (54) of the housing unit (50) is closed by the cover part (44) of the lens unit (40), and the one or more insertion openings (49) of the lens unit (40) are closed by the one or more side walls of the housing unit (50), characterized in that the method further comprises the following steps: • Providing a first pointed part (56bb) extending around the bottom opening (52) of the housing unit (50) and a second pointed part (58bb) extending around the cover part opening (54) of the housing unit (50), and • Simultaneously implementing a first welding trace (56) and a second welding trace (58) in the regions of the first pointed part and the second pointed part respectively.

2. The method according to claim 1, wherein It further comprises the following steps: Arranging two opposite edges of the printed circuit board unit (30) on or in two guide rails (46, 48) such that the printed circuit board unit (30) is supported by the lens unit (40), the two guide rails being provided by the lens unit (40), in particular by two opposite side walls of the lens unit (40).

3. The method according to claim 1 or 2, characterized in that, It further comprises the following steps: • Providing one or more connector pins (32, 34) for the printed circuit board unit (30), wherein the one or more connector pins (32, 34) extend into a second insertion opening (49) among the one or more insertion openings (49) of the lens unit (40), and / or • Providing at least one extension part (36) for the printed circuit board unit (30), wherein the at least one extension part (36) extends into a third insertion opening (49) among the one or more insertion openings (49) of the lens unit (40).

4. The method according to claim 3, characterized in that The second insertion opening and / or the third insertion opening (49) are provided by the first insertion opening (49).

5. The method according to any one of the preceding claims, characterized in that, The method further includes the following steps: • Positioning the bottom (42) of the lens unit (40) by a first stepped extension (56ba) of the housing unit (50) around its bottom opening (52), and / or • Positioning the cover part (44) of the lens unit (40) by a second stepped extension (58ba) of the housing unit (50) around its cover opening (54).

6. The method according to any one of the preceding claims, characterized in that, The method further includes the following steps: Providing at least one extension (36) for the printed circuit board unit (30), wherein the at least one extension (36) extends into a third insertion opening (49) among the one or more insertion openings (49) of the lens unit (40), and in particular, the second insertion opening and / or the third insertion opening (49) are provided by the first insertion opening (49).

7. The method according to any one of the preceding claims, characterized in that, The method further includes the following steps: Providing at least one connector extension (51) by the housing unit (50) for inserting a connector for connecting the printed circuit board unit (30).

8. The method according to claim 7, characterized in that the at least one connector extension (51) is provided by a side wall enclosing the one or more insertion openings (49) of the lens unit (40), and is particularly formed on an outer surface of the side wall in the region of an internal step (59), and / or an isolation frame (53) extends into the at least one connector extension (51), and particularly extends between two of the one or more connector pins (32, 34) of the printed circuit board unit (30).

9. The method according to any one of the preceding claims, characterized in that the one or more light sources are provided in the form of at least two, preferably three light source units, and each light source unit includes an LED unit (20, 21, 22).

10. The method according to any one of the preceding claims, characterized in that the lens unit (40) is made of a transparent and / or light-transmitting plastic material, and / or the housing unit (50) is made of an opaque and / or light-impermeable plastic material.

11. The method according to any one of the preceding claims, characterized in that the housing unit (50) is formed with an attachment part (60), wherein the attachment part (60) is adapted to mount the lamp unit (10) to a rear-view device by a clip, snap and / or latch connection, and / or wherein preferably, the attachment part (60) is provided with an attachment extension (61), and / or wherein preferably, the attachment part (60) has a T-shaped cross-section.

12. An external rear-view device having at least one rear-view element arranged in a head assembly and at least one lamp unit (10) manufactured by the method according to any one of the preceding claims for providing a side turn indicator, blind spot detection, a marker lamp, a door handle lamp and / or a proximity lamp.

13. The external rearview device according to claim 12, wherein: Preferably, the illumination surface of the lamp module (10) provided by the bottom (42) of the lens unit (40) is flush with the outer surface of the external rearview device.

14. The external rearview device according to claim 12 or 13, further comprising: A base assembly for attachment to a vehicle, wherein the head assembly is movable relative to the base assembly.

15. The external rearview device according to any one of claims 12 to 14, wherein: At least one first lamp module (10) is attached to the head assembly, in particular to the head frame (200), and / or At least one second lamp module (10) is attached to the base assembly, wherein preferably, the attachment portion (60) of the lamp module (10) provides a releasable clip, snap, and / or latch connection.

16. The external rearview device according to any one of claims 12 to 15, wherein: A connector (100) is inserted into each connector extension (51) of the lamp module (10) for sealing thereof.

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