Optical solid body made of solid transparent material and method

Abstract

The invention relates to an optical solid body (10) made of a solid transparent material for use in a light module (12) of a motor vehicle lighting device (14). The optical solid body (10) comprises a light coupling-in part (16), via which light from a light source (18) of the motor vehicle lighting device (14) can be coupled into the optical solid body (10), and a light coupling-out part (22), via which light from the light source (18) can be coupled into the optical solid body (10), at least a portion of the light coupled into the optical solid body (10) is coupled out of the optical solid body (10) via the light coupling-out portion such that the coupled-out light is used to generate at least a portion of a light distribution of the motor vehicle lighting device (14) in front of the motor vehicle. The optical solid body (10) further comprises an optically active layer (24) arranged in the beam path between the in-coupling portion (16) and the out-coupling portion (22), the optically active layer being designed to alter incident light, where the optically active layer (24) comprises at least one film (24a) and is arranged in the interior of the optical solid body (10). It is proposed that the at least one film (24a) has a three-dimensional shape, configuration and / or structure and is overmolded on at least one of its surfaces with the transparent material of the optically solid body (10).

Description

[0001] This invention relates to a solid optical body made of a solid transparent material, used in the optical module of a vehicle lighting device. The solid optical body includes an optical coupling input portion and an optical coupling output portion. Light from a light source of the vehicle lighting device is coupled into the solid optical body via the optical coupling input portion. At least a portion of the light coupled into the solid optical body is coupled out of the solid optical body via the optical coupling output portion, such that the coupled-out light is used to generate at least a portion of the light distribution of the vehicle lighting device in front of the vehicle. Furthermore, the solid optical body has an optically active layer disposed in the beam path between the optical coupling input portion and the optical coupling output portion. This optically active layer is designed to modify the incident light, and is formed within the solid optical body.

[0002] Furthermore, the present invention relates to a method for manufacturing such optical solid bodies.

[0003] Furthermore, the present invention relates to an optical module for a motor vehicle lighting device, the optical module having a light source and such an optical solid body, wherein the light source is designed and arranged and aligned relative to the optical solid body such that it emits light in a main emission direction in the direction of the light coupling input portion of the optical solid body, and wherein the optical solid body is designed to use an optically active layer comprising at least one film to modify the light coupled into the optical solid body via the coupling input portion, at least a portion of the coupled input light being projected onto the at least one film, such that the light coupled out via the coupling output portion of the optical solid body generates at least a portion of the light distribution of the motor vehicle lighting device in front of the motor vehicle.

[0004] Finally, the present invention also relates to a vehicle lighting device having a housing with a light emission opening closed by a cover plate, and a light module inside the housing that projects light in front of the vehicle to generate a light distribution or a portion thereof for the vehicle lighting device. The vehicle lighting device is preferably designed as a vehicle headlight.

[0005] Optical modules with such a solid optical body are known in various embodiments from the prior art. They have the advantage that they can be designed to be particularly small. Furthermore, they are inexpensive to manufacture because, due to the one-piece solid optical body, the alignment and adjustment of various components of the optical module relative to each other (e.g., the primary lens or reflector relative to the mirror stop) can be omitted.

[0006] For example, a light module of the aforementioned type used in a headlight of a motor vehicle is known from EP 1 357 333 A2. The optical solid body has a coupling input portion on its lower side, located opposite the light source in the form of an LED. Furthermore, the optical solid body has a primary optical portion with a reflective surface, disposed on the upper side of the optical solid body opposite the coupling input portion. On the lower side of the optical solid body, next to the coupling input portion, an optical active layer in the form of a horizontal mirror stop is arranged. An intermediate image generated at the leading edge of the mirror stop in the intermediate image plane is projected in front of the vehicle by the projection lens of the light module as the low beam distribution of the motor vehicle headlight. The projection lens is formed independently of the optical solid body and is arranged downstream of the coupling output portion of the optical solid body in the beam path. Both the primary lens portion and the mirror stop are formed at the outer boundary surface of the optical solid body. Using a known optical solid body, only one type of light distribution can be generated, such as the low beam distribution in EP 1 357 333 A2. Different types of light distributions, such as high beam distributions, must be generated by different optical modules of the lighting device.

[0007] An optical solid body used in the light module of a headlight of the type of motor vehicle mentioned at the beginning is known from DE 10 2022 101 928 A1. In the case of the known optical solid body, the optical active layer may include a flexible film. During the manufacture of the optical solid body, a transparent material is first injected into a mold, and then the film is applied to the transparent material. In this process, the film takes on the shape of the cured transparent material to which it has been applied. The cured material forms a support structure, which, it can be said, gives the film the desired three-dimensional shape and holds it in that shape during the intended use of the optical solid body. Without the support structure, the film does not have sufficient inherent rigidity to maintain its own three-dimensional shape.

[0008] The following example uses a film designed as a reflective aperture to illustrate the shortcomings of the prior art. A reflective aperture is used to form a light-dark boundary for a vehicle lighting system. With respect to its substantially horizontal surface area, the aperture is used to form a light-dark boundary with an approximately horizontal orientation. Below the light-dark boundary, the low beam illuminates the lane ahead of the vehicle, while above the boundary, almost no light reaches, in order to prevent oncoming road users or those traveling in front of a private vehicle from being dazzled.

[0009] Depending on the traffic type, the orientation of the light and dark boundary can vary. For example, European standards specify so-called asymmetrical light and dark boundaries, which define a first horizontal section on the vehicle's own traffic side, a second horizontal section on the oncoming traffic side (also horizontal but located below the first horizontal section), and a sloping transition between the two horizontal sections. According to Japanese standards, a vertical transition is provided between the two horizontal sections. It should be understood that the described orientation of the light and dark boundary is not limited to the countries mentioned, but can also be used in other countries. Furthermore, it is conceivable to have a light module with a solid optical body and a reflective aperture designed to produce at least a near-horizontal light and dark boundary. This is especially true for light modules that only generate a portion of the light distribution of a motor vehicle's headlights. Regarding right-hand and left-hand traffic, the design of different orientations of the light and dark boundary or the three-dimensional structure of the reflective aperture can also be used depending on the traffic type.

[0010] The optically active layer formed into a film can not only be responsible for or influence the orientation of the light-dark boundary, but also for or influence other properties of the resulting light distribution. For example, it is conceivable that the top illumination value and / or optical interference effect of the resulting near-beam light distribution in the region of the vertical and / or horizontal light-dark boundary of the light distribution may be affected.

[0011] Therefore, the design of the optical module or optical solid body to suit different traffic types depends on the shape, configuration, and / or three-dimensional structure of the membrane. If, for example, the type or design of the light-dark boundary of the resulting light distribution of a motor vehicle headlight is to be adapted to different traffic types, for example in the prior art, the mold must be modified or different mold inserts used to give the injected transparent material (to which the flexible membrane is subsequently applied) the correct shape, which depends on the traffic type for which the motor vehicle headlight with the optical module containing the optical solid body is intended. In order to manufacture optical solid bodies for different traffic types, different molds or mold inserts are required in the prior art. Therefore, even for one traffic type, and especially for different traffic types, the manufacture of well-known optical solid bodies is complex and cost-intensive.

[0012] In the prior art, different molds must be used to adapt optical modules or motor vehicle headlights to traffic types. This usually requires manufacturing very similar molds multiple times, or keeping mold inserts in stock, which requires reprocessing the molds to manufacture optical accessories and adapt them to different traffic types.

[0013] Therefore, based on the described prior art, the present invention is based on the aim of making the manufacture of known optical solid bodies, especially optical solid bodies for different traffic types, simpler and more flexible.

[0014] This objective is achieved by an optical solid body having the features of claim 1. In particular, starting from the type of optical solid body mentioned at the beginning, it is proposed that the at least one film has a three-dimensional shape, configuration and / or structure, and is injection molded with a transparent material of the optical solid body overlaid on at least one of its surfaces.

[0015] When manufacturing optical solid bodies for the same traffic type, but particularly for different traffic types, no changes to the mold or alternative mold inserts are required. Due to the membrane's three-dimensional shape, configuration, and / or structure, the membrane can replace the mold inserts and fulfill its function. Therefore, the membrane already possesses its desired three-dimensional shape, configuration, and / or structure before being inserted into the mold, and retains this three-dimensional shape, configuration, and / or structure even after the membrane has been inserted into the mold and during the injection of transparent material into the mold. The optical solid bodies according to the invention can be manufactured more simply and flexibly, at least in the area of ​​the design corresponding to the traffic type responsible for the resulting light distribution, or in areas associated with that design. Another advantage is the reduced effort in mold manufacturing, as only one mold is required and inserts are not needed, thus enabling much faster turnarounds without significant installation time.

[0016] The membrane, inserted into the mold, is injection molded with a transparent material overlapping an optically solid body on at least one of its surfaces. After curing, the transparent material has a shape, configuration, and / or structure defined by the three-dimensional shape, configuration, and / or structure of the membrane on the side defined by the membrane.

[0017] In this invention, an optically active layer is formed or disposed within an optically solid body. In other words, the optically active layer is surrounded at least on one side, and preferably on all sides, by a transparent material of the optically solid body. This opens up entirely new possibilities for the smallest possible multifunctional optically solid body, which will be explained in detail below.

[0018] A light source emits light in a principal radiation direction. This principal radiation direction can be oriented parallel to, inclined to, or perpendicular to the axis (e.g., optical axis) of the optical solid body. When slightly inclined to or parallel to the optical axis, light coupled into the optical solid body can be directed directly toward the optically active layer within the optical solid body, without needing to be deflected within the optical solid body on its way there. With a highly inclined or perpendicular orientation to the optical axis, the optical solid body may need to have a principal optical section designed to focus at least a portion of the light coupled into the optical solid body and / or redirect it in the direction of the optically active layer of the optical solid body. The principal optical section may include a reflective surface formed externally on the outer boundary surface of the optical solid body, preferably opposite the coupling input portion. Alternatively, a primary lens portion may also be formed or disposed within the optical solid body via the optically active layer, particularly the reflective layer. It is conceivable that the optical solid body has multiple optically active layers. These may have the same or different functions. However, the primary lens portion may also be disposed on or formed therefrom the coupling input portion. The primary lens section can be designed as a converging lens section that focuses the passing light rays and / or deflects them in the direction of the optical axis.

[0019] This invention enables the fabrication of an optically active layer within a solid optical body for realizing apertures, and particularly for mirror apertures, spectral converters, filters, etc. This allows for a very compact design of multifunctional optical modules. Furthermore, the internal optically active layer can also be used to define the internal boundaries between the optical and non-optical regions of the solid optical body. The non-optical regions can be used for other purposes, such as as fasteners. In summary, installation effort can be reduced because only a single solid optical body with an integrated aperture section and / or an integrated main optical section is required, instead of having the aperture section and / or main optical section as separate components on the outer boundary surface of the solid optical body. Functional integration can be increased by partially or completely separating the optical path.

[0020] The optical solid body is made of a solid, transparent material, such as glass or plastic, particularly PC or PMMI, due to their good temperature stability. However, PMMA can also be used as a material if the temperature within the optical solid body can be confined. Preferably, a light-emitting semiconductor element, particularly an LED (light-emitting diode) or LD (laser diode), is used as the light source. Of course, multiple light sources can be assigned to a single optical solid body, and light can be coupled into the optical solid body simultaneously, individually, or in groups.

[0021] Various designs and / or functions of the optical active layer are conceivable. For example, if designed accordingly, the optical active layer can function as an aperture stop, particularly a light-shielding aperture or a mirror aperture. Among other things, the present invention enables the realization of the function of an aperture stop, particularly a mirror aperture, within a solid optical body, without relying on reflections at the outer boundary surface of the solid optical body.

[0022] The region of the optical solid body behind the aperture, shielded by the optically active layer (i.e., where no light reaches and therefore can be referred to as the non-optical region), can perform non-optical tasks, such as serving as a fastening component for securing the optical solid body or optical module to a lighting device or the like. This is not possible in the prior art because the aperture portion and / or the primary lens portion would be externally arranged on the boundary surface of the optical solid body.

[0023] To arrange the aperture within the optical solid body, a film or coating with absorptive and / or reflective properties can be introduced into the material of the optical solid body as an intermediate step during the manufacturing process, such as using a multilayer injection molding process or a multi-part multilayer process. Specifically, the film or coating can be applied to a portion of the optical solid body manufactured in a previous manufacturing step and subsequently injection molded or molded over another layer of material from the optical solid body in a subsequent step.

[0024] According to an advantageous improvement of the invention, the proposed design of the three-dimensional shape, configuration, and / or structure depends on the type of traffic for which the lighting device for a motor vehicle, having an optical module with an optical solid body, is intended. This means that the membrane can be differently shaped, designed, and / or structured according to the type of traffic for which the optical solid body or the optical module equipped with the optical solid body is intended. To manufacture an optical solid body for a specific type of traffic, it is only necessary to insert a specific membrane intended for that type of traffic into a mold and overmold it with a transparent material on at least one side. To manufacture an optical solid body for a different type of traffic, it is only necessary to insert a different membrane intended for another type of traffic into a mold and overmold it with a transparent material on at least one side. There is no need to change the mold or keep it usable using different mold inserts.

[0025] According to a preferred embodiment of the invention, the proposed three-dimensional shape, configuration, and / or structure is designed for one of the following traffic types or to achieve one of the following lighting functions: a target reduction in luminous intensity in the area of ​​the light distribution at right-hand traffic, left-hand traffic, and a legally measured point, and a target increase in luminous intensity in the area of ​​the low-beam light distribution above the horizontal light-dark boundary of the light distribution. Furthermore, different traffic types may also include a membrane for generating or forming a light distribution defined or adjusted according to the laws of different countries or regions. In particular, the membrane is used to generate or form the main light distribution of the headlight module of a motor vehicle. Such a main light distribution is, for example, low beam, high beam, variable light distribution, urban lighting, rural road lighting, highway lighting, partial high beam, etc., or a portion thereof, such as a low beam or high beam spotlight or low beam or high beam base lamp.

[0026] The proposed membrane, having a three-dimensional shape, configuration, and / or structure, extends along or parallel to the axis of the optical solid body, preferably along the longitudinal axis or optical axis of the optical solid body. It is also conceivable that the main surface area of ​​the membrane extends obliquely to or perpendicular to the axis of the optical solid body.

[0027] Advantageously, at least one membrane with a three-dimensional shape, configuration, and / or structure has a main surface area that, in the case of a vehicle lighting device installed in a motor vehicle and having a light module with an optical solid body, is substantially parallel to the lane extension where the motor vehicle is parked or traveling. To determine the main surface area of ​​the membrane, for example, an imaginary interpolation plane closest to each surface portion can be provided. According to this embodiment, this imaginary plane is substantially or approximately parallel to the road extension, i.e., its surface area extends approximately in a horizontal plane.

[0028] Of course, membranes with three-dimensional shapes, configurations and / or structures may also have a main surface area. In the case of a motor vehicle lighting device installed in a motor vehicle and having a light module with an optical solid body, the main surface area is not approximately parallel to the lane extension where the motor vehicle is parked or traveling, i.e., it is inclined to or perpendicular to the lane extension.

[0029] Particularly preferred is that the at least one membrane has inherent rigidity, allowing it to maintain a designed three-dimensional shape, configuration, and / or structure. This at least one membrane is incorporated into the designed three-dimensional shape, configuration, and / or structure before being overmolded with a transparent material, and the designed three-dimensional shape, configuration, and / or structure corresponds to the three-dimensional shape, configuration, and / or structure of the overmolded membrane in the finished optical solid body. In this way, the membrane can be inserted into the mold as an alternative to one or more mold inserts, which significantly simplifies the manufacture of optical solid bodies, particularly for different optical solid bodies used in different traffic types.

[0030] Particularly preferred is that the at least one film is designed as a reflective aperture that defines or generates the light-dark boundary of the low beam headlight distribution in front of the vehicle's lighting device. The reflective aperture has a metallized layer on at least the surface of the optical solid body facing the light coupling input portion. At this point, light entering the optical solid body is reflected or mirrored. Alternatively, the surface of the reflective aperture facing the light coupling input portion of the optical solid body may also be designed and arranged in the optical solid body in such a way that the incident light is completely reflected. The light reflected at the reflective aperture is coupled out of the optical solid body via the coupling output portion and reaches the illuminated area of ​​the light distribution, or, in the case of the low beam headlight distribution, the area below the light-dark boundary. The edge of the reflective aperture, preferably the front edge (if the surface area of ​​the reflective aperture is along the axis of the optical solid body, particularly along the longitudinal axis or optical axis) or the upper edge (if the surface area of ​​the reflective aperture is perpendicular to the axis of the optical solid body), defines the position and orientation of the light-dark boundary.

[0031] However, it is also conceivable that the surface of at least one film, or at least the coupling input portion of the film facing the optical solid body, has light scattering properties. In this case, the film can randomly or selectively scatter incident light. In this way, excessively high luminous intensity values ​​can be avoided in certain areas of the light distribution by redirecting the light to other illuminated areas of the light distribution, or minimum luminous intensity values ​​can be achieved by redirecting light from areas where high luminous intensity is not desired or expected to those areas of the light distribution where certain minimum luminous intensity values ​​are to be achieved. The scattered light is preferably also used to generate the light distribution without loss.

[0032] According to another preferred embodiment, it is proposed that the at least one film has a lower refractive index than the transparent material used for overlaying the at least one film. Specifically, it is proposed that the at least one film has a layer with a lower refractive index than the transparent material used for overlaying the at least one film, at least on the surface of the light coupling input portion facing the optical solid body. This allows light coupled into the transparent material of the optical solid body to be affected when projected onto the layer with the lower refractive index. The transition from the transparent material to the layer with the lower refractive index forms a boundary surface. Light is preferably completely reflected at the boundary surface.

[0033] The potential object of the present invention is also achieved by a method having the features of claim 10. In particular, based on the manufacturing method of the type described above, it is proposed that the method include the following steps:

[0034] - Provide membranes with defined three-dimensional shapes, configurations, and / or structures.

[0035] - Coated at least on the first surface of the film,

[0036] - Insert the membrane into the mold, and

[0037] - The first surface of the membrane is injection molded with a transparent material overlapping an optical solid body.

[0038] The advantage of this method is that the manufacture of the optical solid body is particularly simple and flexible because special mold inserts adjacent to or within the membrane can be eliminated. The membrane itself, with its defined three-dimensional shape, configuration, and / or structure, replaces the mold insert or takes over its function. When manufacturing different optical solid bodies intended for different modes of transport, there is no need to change the injection mold or modify the mold, nor is it necessary to retain and use different mold inserts.

[0039] The first surface of the membrane is preferably the surface of the coupling input portion of the membrane facing the optical solid body. The first surface of the membrane may be coated with a metallization layer (e.g., for specular reflection of incident light) and / or a layer with a refractive index lower than that of the transparent material used for overlaying at least one membrane (e.g., for total internal reflection). Of course, it is also conceivable to have a coating with layers having other properties (e.g., with light scattering properties).

[0040] According to an advantageous improvement of the invention, it is proposed that after the first surface of the inserted membrane has been overmolded with a transparent material of an optically solid body, the relatively positioned second surface of the inserted membrane is also overmolded with a transparent material of an optically solid body. Since there is no need for a separate mold insert that must be removed again after the injection and curing of the transparent material, the overmolding of the two surfaces of the inserted membrane with the transparent material of an optically solid body can also be performed simultaneously or at least partially overlapped in time.

[0041] More than one membrane may be arranged within the optical solid body. In this sense, it is proposed that an additional membrane with a three-dimensional shape, configuration, and / or structure be placed in a mold on an overmolded transparent material of the optical solid body, and overmolded on at least one of its surfaces with the transparent material of the optical solid body. This additional membrane does not necessarily need to have inherent rigidity such that it retains the three-dimensional shape, configuration, and / or structure of the design brought in prior to the overmolding with the transparent material. This additional membrane may be designed as a flexible membrane.

[0042] Advantageously, the three-dimensional shape, configuration, and / or structure of the membrane are defined according to the traffic type for which the motor vehicle lighting device with an optical module having an optical solid body is intended. Preferably, the three-dimensional shape, configuration, and / or structure are defined for one of the following traffic types or for achieving one of the following lighting functions: a target reduction in luminous intensity in the area of ​​light distribution at right-hand traffic, left-hand traffic, and a legal measurement point, and a target increase in luminous intensity in the area of ​​low beam light distribution above the horizontal light-dark boundary of the light distribution.

[0043] The objective upon which this invention is based is also achieved by an optical module having the features of claim 15. In particular, starting with the type of optical module mentioned at the beginning, it is proposed that the optical module have an optical solid body according to the invention.

[0044] It is conceivable that an optical module has multiple light sources and / or multiple solid optical bodies. Light-emitting semiconductor elements, particularly LEDs or LDs, can be used as light sources. Multiple light sources can be assigned to a single solid optical body and can couple light into the solid optical body simultaneously, individually, or in groups. Multiple light sources can be arranged on a common circuit board and in contact on the common circuit board. Multiple solid optical bodies can be designed as separate components or a single integrated component. Multiple light sources and multiple solid optical bodies can be part of a matrix optical module, where the partial light distribution of each solid optical body can complement and / or superimpose with each other to form the resulting light distribution of a motor vehicle lighting device. Variable light distributions, such as partial high beam distributions, can be produced by selectively turning on / off or dimming the light sources assigned to each solid optical body. In a high beam distribution, dimming or turning off the corresponding light source obscures the area where road users traveling ahead or oncoming road users are detected, preventing dazzle for road users.

[0045] According to an advantageous improvement of the invention, the proposed optical module has a projection lens arranged downstream of the coupling output portion of the optical solid body in the beam path and designed to image an intermediate image formed in an intermediate image plane as a light distribution for a vehicle lighting device or as part of a light distribution in front of the vehicle, the intermediate image plane preferably being arranged within the optical solid body. The projection lens may be formed from the coupling output portion of the optical solid body.

[0046] Finally, the potential object of the present invention is also achieved by a vehicle lighting device having the features of claim 18. In particular, starting from the type of vehicle lighting device mentioned at the beginning, it is proposed that the vehicle lighting device have at least one light module according to the present invention.

[0047] The lighting device for motor vehicles using the optical solid body according to the invention is not limited to a specific type of lighting device, and can be designed, for example, as a headlight for generating driving light or main light distribution (e.g., low beam and / or high beam), or as a lamp for generating lighting functions, such as a fog lamp designed for generating fog lights, or a turn signal designed for generating cornering lights or turning lights.

[0048] The at least one light module can be rigidly or movably arranged within the lighting device of a motor vehicle or its housing. In particular, it is conceivable that the at least one light module can be pivotally arranged within the housing of the lighting device. Dynamic turn signal functionality can be achieved by specifically pivoting the at least one light module in the horizontal direction. However, the horizontal pivoting of the light module can also be used to generate partial high beams. The partial high beam distributions of the two light modules each have vertical light-dark boundaries and are positioned relative to each other such that other road users are located in the shaded area of ​​the resulting light distribution between the two vertical light-dark boundaries. Dynamic headlight range control can be achieved by specifically pivoting the at least one light module in the vertical direction. However, if traffic conditions permit, the vertical pivoting of the light module can also be used to generate highway lighting by increasing the light-dark boundaries of the low beam distribution on highways.

[0049] Further features and advantages of the invention will now be explained in more detail with reference to the accompanying drawings. Features shown in the drawings may also be essential to the invention itself, even if they are not shown in the drawings and are not expressly mentioned in the description. Furthermore, the various features shown in the drawings can be combined with each other in any way, even if such combinations are not shown in the drawings and are not expressly mentioned in the description. In the drawings:

[0050] Figure 1 A vertical longitudinal section shows an optical module according to the invention for a lighting device for a motor vehicle according to a first exemplary embodiment, the optical module having an optical solid body according to the invention;

[0051] Figure 2 Shown in horizontal longitudinal section Figure 1 Optical modules;

[0052] Figure 3 A vertical longitudinal section shows an optical module according to the invention for a lighting device for a motor vehicle according to a second exemplary embodiment, the optical module having an optical solid body according to the invention;

[0053] Figure 4 Shown in horizontal longitudinal section Figure 3 Optical modules;

[0054] Figure 5A horizontal longitudinal section is shown of an optical module according to the invention for a lighting device for a motor vehicle according to a third exemplary embodiment, the optical module having a plurality of optical solid bodies according to the invention;

[0055] Figure 6 A horizontal longitudinal section is shown of an optical module according to the invention for a lighting device for a motor vehicle according to a fourth exemplary embodiment, the optical module having a plurality of optical solid bodies according to the invention;

[0056] Figure 7 It shows the basis opposite to the direction of light emission. Figures 1 to 4 Front view of the optical solid body of any of them;

[0057] Figure 8 It shows according to Figure 7 A first alternative embodiment of the optically active layer inside the optically solid body;

[0058] Figure 9 It shows according to Figure 7 A second alternative embodiment of the optically active layer inside the optically solid body;

[0059] Figure 10 A motor vehicle lighting device according to the invention, based on a preferred embodiment, is shown;

[0060] Figures 11a to 11c Various examples of structured membranes for optical solid bodies targeting different traffic types are shown;

[0061] Figures 12a to 12d Different steps for manufacturing an optical solid body according to the invention are shown, the optical solid body having a structured partially metallized film;

[0062] Figures 13a to 13b Different steps for manufacturing an optical solid body according to the invention are shown, the optical solid body having a structured film with a low refractive index;

[0063] Figures 14a to 14b Different steps for manufacturing an optical solid body according to the invention are shown, the optical solid body having a plurality of structured metallization films;

[0064] Figures 15a to 15b Different steps for manufacturing an optical solid body according to the invention are shown, the optical solid body having multiple structured films having a low refractive index;

[0065] Figures 16a to 16b Different views of an optical solid body according to the invention are shown, the optical solid body having a structured film along the optical axis;

[0066] Figures 17a to 17b Various examples of structured films for optical solid bodies are shown, which are used to increase or decrease the luminous intensity in the resulting light distribution of a motor vehicle lighting device;

[0067] Figures 18a to 18c Different examples of structured films for optical solid bodies are shown, which are used to eliminate crosstalk between the low beam and high beam regions of the resulting light distribution of a motor vehicle lighting device;

[0068] Figure 19 An example of a structured film for an optical solid body is shown, which is used to change the resulting light distribution of a motor vehicle lighting device in a transitional region between the low beam and high beam regions of the resulting light distribution;

[0069] Figures 20a to 20b Different views of the optical solid body according to the invention are shown, the optical solid body having a structured membrane for Petzval adaptation; and

[0070] Figure 21 A flowchart of a method for manufacturing an optical solid body with a structured film according to the present invention is shown.

[0071] exist Figure 1 In this designation, the optical solid body according to the invention is generally indicated by reference numeral 10. The optical solid body 10 is made of a solid transparent material. This material is, for example, glass or plastic, particularly PC or PMMI. It is also conceivable to use PMMA or another transparent plastic. The optical solid body 10 is designed as part of the optical module 12 used in a motor vehicle lighting device 14 (see Figure 14). Figure 10 ).

[0072] exist Figure 10 In the illustration, the lighting device 14 according to the invention is shown in the form of a headlight for a motor vehicle. The lighting device 14 has a housing 34, preferably made of plastic, and includes a light-emitting opening 36, which is closed by a transparent cover plate 38. The cover plate 38 is made of glass or plastic and may be formed with an optically active element (e.g., a cylindrical lens, prism, or the like) that scatters light, particularly in the horizontal direction. However, preferably, the cover plate 38 is designed as a so-called transparent plate without optically active elements. The lighting device 14 is designed for mounting in a corresponding mounting opening of a motor vehicle. A light module 12 with an optical solid body 10 according to the invention is arranged inside the housing 34. Multiple light modules 12 may also be arranged in the housing 34. Furthermore, it is conceivable that... Figure 10Other light modules, symbolically indicated by reference numeral 13 in the accompanying drawings, are arranged inside the housing 34. These light modules are designed to perform at least a portion of the functions of lighting (e.g., indicator lights, turn signals or cornering lights, daytime running lights, position lights, etc.) or headlight functions (e.g., low beam main headlight, low beam spotlight, high beam main headlight, high beam spotlight, etc.).

[0073] The motor vehicle lighting device 14 that can use the optical solid body 10 according to the invention is not limited to a specific type of lighting device, and can be designed, for example, to generate headlights or main light distribution (e.g., low beam, high beam, variable light distribution, city lights, rural road lights, highway lights, partial high beams or a portion thereof), fog lights designed to generate fog lights, cornering lights designed to generate cornering lights or turning lights, or daytime running lights designed to generate daytime running lights.

[0074] The optical solid body 10 includes an optical coupling input portion 16, through which light from the light source 18 of the optical module 12 can be coupled into the optical solid body 10. Figure 1 In this example, the optical solid body 10 includes two coupling input sections 16a and 16b, each assigned a light source 18a and 18b. In this example, the light sources 18a and 18b are each designed as light-emitting semiconductor elements, such as LEDs (light-emitting diodes) or LDs (laser diodes). The light sources 18a and 18b can be mounted on a common circuit board 20 and thus electrically contacted. However, it is also conceivable to use light-emitting semiconductor elements without a circuit board. Between the light source 18 and the coupling input section 16, a beam-focusing lens (so-called auxiliary lens) can be arranged (not shown) to focus the light emitted by the specific light source 18 and guide the light in the direction of the corresponding coupling input section 16. For example, the beam-focusing lens can consist of a reflective-refracting optical accessory, wherein the central portion of the emitted beam is focused by a condenser lens, and at least a portion of the remaining light enters the optical accessory via a surface extending substantially parallel to the optical axis and is focused at the boundary surface of the optical accessory using total internal reflection (TIR).

[0075] Furthermore, the optical solid body 10 includes a light-coupled output portion 22, through which at least a portion of the light coupled into the optical solid body 10 is coupled out, such that the coupled-out light is used to generate at least a portion of the resulting light distribution of the vehicle lighting device 14 in front of the vehicle. Finally, the optical solid body 10 includes an optically active layer 24 disposed in the beam path between the coupling input portion 16 and the coupling output portion 22, the layer being designed to modify the incident light. In the context of this invention, the optically active layer 24 includes a film 24a having a three-dimensional shape, configuration, and / or structure. In particular, a specific shape, configuration, and / or structure of the mirror stop is imprinted into the film 24a.

[0076] At least a portion of the light coupled into the optical solid body 10 strikes and is altered by the optical active layer 24. Specifically, the optical active layer 24 generates an intermediate image in an intermediate image plane. The intermediate image plane is preferably located within the optical solid body 10. The intermediate image is projected in front of the vehicle by a secondary or projection lens (see [link]). Figure 3 and Figure 4 This produces the desired light distribution. Preferably, the structured film 24a is designed to absorb, transmit, reflect, refract, diffract, convert the spectrum, and / or filter incident light, either wholly or partially.

[0077] In the example shown here, the structured film 24a of the optical solid body 10 is arranged and designed such that it separates the first region 26 of the optical solid body 10 from the second region 28 of the optical solid body 10. The first light source 18a of the optical module 12 is assigned to the first region, and the second light source 18b of the optical module 10 is assigned to the second region. Of course, it is also conceivable to assign more than one light source 18 to each of the first region 26 and the second region 28 of the optical solid body 10. The two regions 26, 28 of the optical solid body 10 are preferably composed of the same solid body optically transparent material, particularly a transparent material having the same refractive index.

[0078] In the example shown here, the common coupling output portion 22 is assigned to two regions 26, 28 of the optical solid body 10. However, it is also conceivable to assign separate coupling output portions 22a, 22b to each of regions 26, 28.

[0079] The structured film 24a can be completely flat or asymmetrical, having a downwardly sloping portion, as described below. The structured film is located on or extends parallel to the axis of the optical solid body 10, specifically the optical axis 30 or two optical axes 30a, 30b of the first region 26 and the second region 28 of the optical solid body 10. The structured film 24a preferably functions as an aperture that deflects the incident light and thereby blocks a specific area of ​​the resulting light distribution in which the blocked light would have reached without the aperture. In particular, the structured film 24a is designed as a mirror aperture that completely or partially reflects the incident light in the direction of the coupling output portion 22.

[0080] The first region 26 of the optical solid body 10 can be designed, for example, to generate a first light distribution of the lighting device 14, and the second region 28 can be designed to generate a second light distribution. The first light distribution is, for example, a low beam light distribution with horizontal light-dark boundaries (e.g., fog lights) or nearly horizontal (asymmetrical) light-dark boundaries (e.g., low beam lights according to the ECE). Preferably, the first light distribution itself satisfies the legal requirements for low beam lights or fog lights. However, it is also conceivable that the first light distribution may be combined only with another light distribution generated by another region of the optical solid body 10 or by another light module to satisfy the legal requirements for low beam lights or fog lights.

[0081] The second light distribution generated by the second region 28 illuminates, for example, the area above the light-dark boundary of the light distribution, and together with the low beam distribution of the first region 26 of the optical solid body 10, generates the high beam distribution. This preferably satisfies the legal requirements for high beams. However, it is also conceivable that the second light distribution may be combined only with the low beam distribution of the first region 26 and another light distribution generated by another region of the optical solid body 10 or by another light module to satisfy the legal requirements for high beams.

[0082] Each of regions 26 and 28 of the optical solid body 10 is assigned a coupling input portion 16a, 16b and a coupling output portion 22a, 22b facing the corresponding light source 18a, 18b. In this example, the two coupling output portions 22a, 22b of the first region 26 and the second region 28 of the optical solid body 10 are combined as mentioned to form a common coupling output portion 22, or formed by a single common coupling output portion 22. The common coupling output portion 22 of the optical solid body 10 can be designed, for example, as a lens.

[0083] In particular, the common coupling output section 22 has an outwardly convex and curved light emitting surface 32.

[0084] A key feature of this invention is that the structured film 24a is not formed or disposed on the outer boundary surface of the optical solid body 10, but rather within the solid body 10 itself. This allows for the realization of a particularly small optical solid body 10 and optical module 12. In particular, for the first time, two different light distributions, especially low beam and high beam, can be achieved through different regions 26, 28 of the optical solid body 10, which is designed as a single component. Furthermore, the optical solid body 10 according to the invention can be manufactured cost-effectively because, due to the one-piece design of the optical solid body 10, the alignment and adjustment of various components relative to each other can be eliminated (e.g., the alignment and adjustment of the structured film 24a relative to the coupling input portion 16 and / or the coupling output portion 22, or the alignment and adjustment of the low beam region 26 relative to the high beam region 28).

[0085] exist Figure 1 and Figure 2 In the example shown, the optical coupling output portion 22 simultaneously forms a secondary or projection lens, particularly a projection lens, which projects an intermediate image from the intermediate image plane in front of the motor vehicle as the final light distribution of the optical module 12. This imaging effect is achieved, in particular, by the outwardly convex, curved light-emitting surface 32 of the coupling output portion 22. The light-emitting surface 32 can be spherically or non-spherically curved. Thus, the additional component in the form of a projection lens is integrated into the optical solid body 10. During the manufacture of the optical module 12 or the illumination device 14, the complex arrangement and alignment of the solid body 10 relative to the projection lens can be eliminated. Furthermore, this solution requires very little installation space.

[0086] In contrast, Figure 3 and Figure 4 In the example shown, a separate secondary or projection lens 40 is arranged downstream of the coupling output portion 22 of the optical solid body 10 in the beam path. In the example shown, the secondary or projection lens 40 is designed as a projection lens with a light incident surface 42 and a light exit surface 44. In the example shown, a projection lens 40 that is biconvex in vertical section is provided (see [link to example]). Figure 3 The projection lens 40 has a convex light incident surface 42 and a convex light exit surface 44. Specifically, the projection lens 40 is designed as a cylindrical lens (see [link to documentation]). Figure 4 Other designs for the secondary or projection lens 40 are also conceivable. The advantage of a single secondary or projection lens 40 is that the refraction of the outgoing light used to image the intermediate image from the intermediate image plane in front of the motor vehicle can be divided into light distributions on multiple light transmission surfaces 32, 42, 44. This allows for a high-resolution light distribution with greater accuracy and results in a greater degree of design freedom.

[0087] As a result of the novel optical solid body 10 with integrated structured film 24a, the secondary or projection lens 40 has a particularly short focal length, which can be, for example, in the range of only 50 mm (+ / - 20 mm). This is a very small value for a motor vehicle headlight 14, since the focal lengths of corresponding secondary or projection lenses in previously known headlights are in the range of at least 100 mm.

[0088] exist Figure 5 In this example, the secondary or projection lens is integrated into the coupling output portion 22 of the optical solid body 10. Specifically, the lens's function is taken over by the light-emitting surface 32 of the coupling output portion 22. In contrast, in... Figure 6 In the example, a separate secondary or projection lens 40 is provided. In a preferred embodiment, the common light emitting surface is designed to be smooth and continuous, particularly with a continuous curvature.

[0089] exist Figure 5 and Figure 6 In the example, the optical axes 30 of the individual optical solid bodies 10 extend parallel to each other. Of course, it is also conceivable that the optical axes 30 extend obliquely to each other, such that they intersect at at least one intersection point, preferably at the common intersection point of the optical axes 30 of all the optical solid bodies 10 of the optical module 12.

[0090] exist Figure 5 and Figure 6 In this process, light coupled into the optical solid body 10 of the optical module 12 can reach adjacent optical solid bodies 10 of the optical module 12. This can have the advantage of homogenizing the resulting light distribution. On the other hand, such crosstalk between optical solid bodies 10 and adjacent optical solid bodies 10 can also be disadvantageous, for example, because it leads to difficult-to-control scattered light and / or because achieving a preferred high-resolution light distribution becomes more difficult. In this case, it can be advantageous to introduce a structured film 24a in the form of a partition wall 84 between the individual or all optical solid bodies 10 into the common optical components forming the optical solid bodies 10, these walls preventing beam crosstalk (see...). Figure 5 In this case, it is proposed that the partition wall 84 have reflective properties on both surfaces. If low crosstalk of the beam is desired, the partition wall 84 can be designed to be partially transparent. It is also advantageous if the partition wall 84 extends with a flat surface. During the manufacture of the common optical component according to the method of the invention, the film 24a can be introduced into the optical component.

[0091] Each of the light sources 18 emits light in its principal radiation direction. The principal radiation direction can be parallel to, tilted to, or perpendicular to the optical axis 30 of the optical solid body 10. In a preferred alignment, it is slightly tilted to or parallel to the optical axis 30 (see figure). Figures 1 to 6As shown in Figure 11), light coupled into the optical solid body 10 can be directly guided in the direction of the structured film 24a of the optical solid body 10, and does not need to be deflected by the optical solid body 10 on its way there. With regard to the same conceivable orientation that is highly inclined or perpendicular to the optical axis 30, as seen in the main radiation direction of the light source 18, the optical solid body 10 may need to have a main optical portion positioned relative to the coupling input portion 16, which is designed to focus at least a portion of the light coupled into the optical solid body 10 and / or deflect it in the direction of the structured film 24a of the optical solid body 10. The primary lens portion may have a reflective surface that is conventionally formed or arranged on the outer boundary surface of the optical solid body 10. Alternatively, the reflective surface forming the primary lens portion may also be formed by an optically active layer, which, in the sense of the invention, is formed or arranged inside the optical solid body 10. Thus, it is conceivable that the optical solid body 10 also has multiple and / or different optically active layers 24.

[0092] The advantage of this invention is that a structured film 24a is fabricated within the optical solid body 10 to realize apertures, particularly mirror apertures, spectral converters, filters, etc. This enables a very compact design of the multifunctional module 12. Furthermore, the internal structured film 24a can also be used to form an internal boundary between the optically active region and the optically inactive region of the optical solid body 10, as light is blocked by the structured film 24a, so no light can penetrate into the optically inactive region. In summary, installation effort can be reduced because only one optical solid body 10 with an integrated aperture arrangement is needed, instead of additional aperture arrangements, and functional integration can be increased through partial separation of the optical path (see...). Figures 1 to 4 ).

[0093] The design and manufacture of the structured film 24a inside the optical solid body 10 are explained in more detail below. Various different designs and / or functions of the structured film 24a are conceivable. Therefore, with appropriate design, the structured film 24a can, for example, function as an aperture stop, particularly a mirror aperture stop (see...). Figures 1 to 6 Among other things, the present invention enables the function of a reflective aperture within an optical solid body 10 without relying on reflections at the outer boundary surface of the solid body 10.

[0094] To arrange the structured film 24a inside the optical solid body 10, the structured film 24a, having absorptive and / or reflective properties, can be introduced into the material of the optical solid body 10 as an intermediate step during the manufacturing of the optical solid body 10, for example, through a multi-layer injection molding process or a multi-part multi-layer process. For this purpose, the film 24a is arranged in a mold, and subsequently injection molded over at least one side with a transparent material layer 26 of the optical solid body 10.

[0095] The membrane 24a possesses such high inherent rigidity that it retains its three-dimensional shape, configuration, and / or structure before being inserted into a mold and overmolded with a transparent material, and this three-dimensional shape, configuration, and / or structure corresponds to the three-dimensional shape, configuration, and / or structure of the overmolded membrane 24a in the finished optical solid body 10. In this way, the membrane 24a can be inserted into a mold as a substitute for one or more mold inserts, which significantly simplifies the manufacture of the optical solid body 10, particularly for the manufacture of different optical solid bodies 10 for different traffic types.

[0096] In subsequent manufacturing steps, the membrane 24a introduced into the mold can be coated or overmolded with another transparent material layer 28 of the optical solid body 10.

[0097] The membrane 24a has a surface that reflects and / or absorbs light, at least on the side facing the light originating from the coupling input portion 16. The absorbing surface can absorb at least a portion of the incident light and block the absorbed portion of the coupled-in light, thereby forming a desired light distribution. The absorbing surface is, for example, smooth, particularly rough and black. Using such a shielding aperture, it is conceivable to form, for example, a shielded area for the light distribution. The edges of the aperture, particularly the leading edge of a horizontal aperture, can be imaged by secondary or projection lenses 32, 40 as the light-dark boundary of the light distribution. The light-dark boundary extends along the transition between the illuminated and shielded areas of the light distribution. The light-dark boundary can have a horizontal or nearly horizontal (asymmetrical) orientation, for example, to produce fog lights or low beams (according to ECE) or a portion thereof. Similarly, the light-dark boundary can have a vertical or nearly vertical orientation, for example, to produce a partial high beam or a portion thereof, in which the area of ​​the light distribution in which other road users are detected is shielded to avoid dazzling them.

[0098] The reflective surface of the structured film 24a can specifically reflect incident light in a manner that does not lose incident light but helps to generate a light distribution (so-called specular reflection). Therefore, a light distribution can be formed with a light-dark boundary, a shaded area above the light-dark boundary, and an illuminated area below the light-dark boundary. This light distribution includes, on the one hand, the light that has passed through the reflector aperture 24, and on the other hand, at least a portion of the light reflected by the reflector aperture 24. In this way, a particularly effective low-beam light distribution can be produced.

[0099] The structured membrane 24a can also be designed to be partially transparent, meaning that a portion of the light incident on the structured membrane 24a passes through the membrane 24a, while another portion of the light is absorbed and / or reflected by the membrane 24a. This has the advantage that a portion of the light transmitted through the structured membrane 24a can reach the inherently shielded area of ​​the low beam light distribution, particularly above the light-dark boundary, and can be used within the range of the light distribution to achieve specific lighting tasks. In this way, for example, top illumination of the low beam light can be achieved above the light-dark boundary.

[0100] The structured film 24a introduced into the optical solid body 10 is preferably designed and formed such that it generates an intermediate image in the intermediate image plane, which can be imaged by the secondary or projection lens 32 or 40 to generate the resulting light distribution in front of the motor vehicle. Specifically, the structured film 24a is designed and formed such that it generates an intermediate image in the intermediate image plane 60 (see...). Figure 2 and Figure 4 The intermediate image can be imaged by secondary or projection lenses 32 or 40 to generate a low beam headlight distribution (e.g., low beam headlights, fog lights, turn signals) or a portion of the high beam headlights in front of the motor vehicle. The intermediate image plane 60 is preferably located inside the optical solid body 10. Very particularly preferably, the intermediate image plane 60 is located at an edge 58, specifically at the leading edge of the aperture device 24 extending parallel to or along the optical axis 30; 30a, 30b of the optical solid body 10. This edge 58 can be imaged by secondary or projection lenses 32 or 40 as the light-dark boundary of the light distribution in front of the motor vehicle.

[0101] The leading edge 58 and the intermediate image plane 60 can have a straight or flat orientation in the planar view (see...). Figure 2 and Figure 4 (not shown). However, preferably, the edge 58 and the intermediate image plane 60 have a curved direction. The curved direction preferably follows the focal point of the exit surface 32 or 44 of the coupling output section 22 or the projection lens 40. This curved shape of the leading edge 58 of the aperture 24 can help correct distortions in the light distribution.

[0102] Furthermore, it is conceivable to design the structured film 24a in such a way that it completely or partially converts the light of the first spectrum coupled to the optical solid body 10 into light of a different spectrum, i.e., changes the color of the light. This can be achieved, for example, by the structured film 24a reflecting and / or absorbing only the light component of a specific spectrum. In this case, it is conceivable, for example, that the structured film 24a is at least partially translucent and has a specific color, such as red, green, or blue, on its surface facing the coupling input portion 16, so as to selectively change the color of the light in the resulting light distribution. The coloring on the surface of the structured film 24a can be applied, for example, by spraying, sputtering, or vapor deposition of a colorant. If the light source 18 used emits only light of a specific color, which cannot be easily changed at the light source 18 itself, it may be useful to change the color of the light. Here, the structured film 24a with spectral conversion properties provides the possibility of easily achievable color correction of the light in the resulting light distribution. This also allows for a simple and low-cost consideration of motor vehicle manufacturers' desire to personalize the color of their vehicle headlights (some manufacturers prefer greenish-white light for headlight functionality, while others prefer blue or pale yellow light).

[0103] Because only a portion of the light coupled into the optical solid body 10 illuminates the structured film 24a and can therefore be completely altered in its spectrum or color, the tinting of light can be slightly changed by the structured film 24a, which has spectral alteration properties. This means that, for example, daylight white light (above 5300K) can be converted into warm white light (below 3300K) with a relatively high yellow component or cool white light (approximately 7000K to 9000K) with a high blue and / or green component.

[0104] Alternatively or otherwise, it is conceivable to design the structured film 24a in such a way that it possesses light-filtering properties. The film 24a reflects only incident light of a specific spectrum. The remaining spectrum of light is transmitted or absorbed. The structured film 24a, in the form of an optical filter, can have a simple colorant coating or more complex alternatives, such as an interference filter. An interference filter can include one or more superimposed diffraction structures. However, an interference filter can also include multiple partially translucent metallic mirror layers (e.g., made of silver or aluminum). The structured film 24a can have optical filtering layers. Optionally, the film 24a includes a transparent carrier layer, upon which various layers are applied that achieve an optical filtering effect on the light that passes through and / or is reflected.

[0105] Figure 7 It shows that according to Figures 1 to 4A view of the optical solid body 10 of any of the components, opposite to the light emission direction 68. According to this embodiment, the proposed structured film 24a has a first flat portion 62 extending from one side 64 of the optical solid body 10 in the direction of the vertical central plane 66 of the optical solid body 10, particularly in the direction of the optical axes 30; 30a, 30b of the optical solid body 10. A horizontal portion 62 (viewed in the light emission direction 68) is arranged on the traffic side of the vehicle itself on the vertical central plane 66 (right side for right-hand traffic; left side for left-hand traffic). The flat portion 62 is used (after projection by the secondary or projection lens 32 or 40) for example, generating a horizontal portion of the asymmetric light-dark boundary of a low beam headlight or low beam spotlight according to ECE. The horizontal portion of the light-dark boundary (viewed in the light emission direction 68) is arranged in front of the motor vehicle on the oncoming traffic side, particularly in the oncoming lane.

[0106] Following the first section 62 is section 70, which preferably slopes downward at a 15° angle and is flat in a view opposite to the light emission direction 68. However, it is also conceivable that the sloped section 70 is curved or even stepped (not shown). The sloped section 70 extends in the direction of the second side 72 opposite to the first side 64 of the optical solid body 10. Section 70 (viewed in the light emission direction 68) is arranged on the oncoming traffic side of the vertical intermediate plane 66. The sloped section 70 is used (after projection by the secondary or projection lens 32 or 40) for example to generate an asymmetrical light-dark boundary for a low beam headlight or low beam spotlight according to ECE standards. The rising portion of the light-dark boundary (viewed in the light emission direction 68) is arranged in front of the motor vehicle on the vehicle's own side, particularly at the lane edge on the vehicle's own side and / or on the vehicle's own lane.

[0107] According to the described example, the structured film 24a, particularly when it is designed as an aperture or mirror aperture, thus has a planar region having a curvature along the optical axis 30; 30a, 30b or along an axis extending parallel to the optical axis 30; 30a, 30b or along the central plane 66. The leading edge 58 of the structured film 24a is preferably curved opposite to the light emission direction 68, as already described above. Therefore, the leading edge 58 of the structured film 24a extends further in the light emission direction 68 on the opposite sides 64, 72 than in the region of the vertical central plane 66 (see...). Figure 2 and Figure 4 ), which extends through at least one of the optical axes 30a and 30b or parallel to at least one of the optical axes.

[0108] exist Figure 8 and Figure 9The diagram shows an alternative embodiment of the structured film 24a, which is opposite to the light emission direction 68. Although both have a common flat portion 62, the design of the downward-sloping portion 70 differs from... Figure 7 The examples are different. In Figure 8 In the example, the inclined portion 70 includes a first partial portion 74 that preferably slopes downward at a 15° angle, followed by a substantially horizontal second partial portion 76, then a rising third partial portion 78, and finally a flat fourth portion 80. The second partial portion 76 extends below the flat portion 62 and preferably extends parallel to it. The third partial portion 78 may rise at a 15° angle or any other angle. The fourth partial portion 80 preferably extends at the same height as the flat portion 62 and coincides with or is parallel to the flat portion.

[0109] exist Figure 9 In the example, the inclined portion 70 includes a first partial portion 82 that is preferably vertically inclined downwards, and adjacent to it is a second partial portion 84 that is substantially horizontal. The second partial portion 84 extends below the flat portion 62 and preferably extends parallel to the flat portion. The first partial portion 82 forms a stepped transition between the flat portion 62 and the second partial portion 84.

[0110] Figures 7 to 9 The shape of the structured membrane 24a, in the form of an aperture or mirror aperture, for right-hand traffic is shown. It should be understood that, for left-hand traffic, the shown orientation of the structured membrane 24a will be approximately mirrored at the vertical center plane 66.

[0111] exist Figure 5 and Figure 6 The image shows two embodiments of an optical module 12 with multiple solid optical bodies 10. In these examples, three solid optical bodies 10 are arranged adjacent to each other. Of course, more or fewer than three solid optical bodies 10 can be arranged adjacent to each other. It is also conceivable that the shown solid optical bodies 10 or other solid optical bodies 10 are arranged overlapping each other and / or offset from each other at an angle. The arrangement of the solid optical bodies 10 depends on the available mounting space in the motor vehicle (the shape and size of the mounting openings in the bodies) and / or design specifications. The solid optical bodies 10 can be arranged side by side on a horizontal plane or on a plane extending inclined to the horizontal plane, so that the upward or downward direction of the solid optical body 10 or its light emitting surface 32 can be observed against the light emission direction 68.

[0112] The various optical solid bodies 10 of the optical module 12, such as Figure 5 and Figure 6As shown, it is preferably designed as a single, commonly manufactured, integrated optical component. Alternatively, each or all of the optical solid bodies 10 of such optical module 12 may be designed as separate optical components (not shown).

[0113] Figure 21 A flowchart is shown of a method for manufacturing an optical solid body 10 with an internally structured membrane 24a according to the present invention. The process begins in step 86.

[0114] Then, in the first method step 88 of the manufacturing process, such as a multilayer injection molding process, the structured membrane 24a is brought into the desired three-dimensional shape, configuration, and / or structure. This can be accomplished by pressure, which, depending on the membrane material, can be pressing, bending, or a similar method. It is conceivable that heat is supplied during the forming of the structured membrane 24a to facilitate the deformation of the membrane 24a and to allow the membrane 24a to subsequently retain its formed shape, configuration, and / or structure. The membrane 24a preferably has such high inherent rigidity that it retains the three-dimensional shape, configuration, and / or structure into which it is brought before being inserted into the mold, and that the three-dimensional shape, configuration, and / or structure corresponds to the three-dimensional shape, configuration, and / or structure of the membrane 24a in the finished optical solid body 10.

[0115] In subsequent method step 90, an optically active layer 24 may be applied to the surface of the structured film 24a facing the light beam coupled in through the coupling input portion 16. The optically active layer 24 is designed to alter the incident light (e.g., reflection, absorption, scattering, etc.). Layer 24 may be a metallization layer, a layer with a refractive index lower than that of the transparent material used for overlapping injection molding of at least one film 24a, or any other layer capable of altering the incident light. Layer 24 may be applied by sputtering, spraying, painting, vapor deposition, etc.

[0116] It is conceivable that switching steps 88 and 90 would allow the film 24a to be coated first, and then brought into the desired three-dimensional shape, configuration, and / or structure.

[0117] The design of the three-dimensional shape, configuration, and / or structure of the structured membrane 24a depends on the traffic type for which the motor vehicle lighting device 14 with the light module 12 having the optical solid body 10 is intended. The three-dimensional shape, configuration, and / or structure of the structured membrane 24a is designed for one of the following traffic types or to achieve one of the following lighting functions: target reduction of luminous intensity in the area of ​​light distribution at the right-hand traffic, left-hand traffic, and legal measurement points, and target increase of luminous intensity in the area of ​​low beam light distribution above the horizontal light-dark boundary of the light distribution.

[0118] Next, in method step 92, the structured membrane 24a is inserted into the mold. The membrane 24a can be inserted into the mold as a substitute for one or more mold inserts, thereby significantly simplifying the manufacture of the optical solid body 10, particularly for different optical solid bodies 10 for different traffic types. Specifically, different mold inserts for designing the optical active layer 24 for different traffic types do not need to be manufactured, kept in stock, or inserted into the mold. To manufacture an optical solid body 10 for a specific traffic type, only the structured membrane 24a designed according to the traffic type needs to be inserted into the mold.

[0119] In subsequent method step 94, the structured membrane 24a, inserted into the mold, is then injection molded onto at least one surface of the transparent material of the optical solid body 10. The structured membrane 24a serves here as a substitute for one or more mold inserts and can shape the transparent material injected into the region adjacent to the membrane 24a into the desired shape of the optical solid body 10. Removing the mold insert after the transparent material has been injection molded or hardened is also unnecessary, as the membrane 24a remains within the formed optical solid body 10.

[0120] If necessary, in another method step 96, the structured membrane 24a inserted into the mold can be injection molded onto at least one other surface using a transparent material of the optical solid body 10. Method steps 94 and 96 can also be performed simultaneously or at least partially overlapping in time.

[0121] If necessary, in method step 98, an additional optically active layer 24 may be inserted into the mold onto the injection material of the optical solid body 10, and subsequently overmolded with another transparent material of the optical solid body 10. This can be done in accordance with the invention or in accordance with the method described in DE 10 2022 101 928A1.

[0122] The method ends in step 100.

[0123] Figures 11a to 11c Various embodiments of the structured membrane 24a for different traffic types are illustrated by way of example, each embodiment being orthogonal in plan view to the optical axis 30; 30a, 30b of the optical solid body 10 into which they are inserted. Different traffic types include right-hand traffic (…). Figure 11a ) and left-side traffic ( Figure 11b ) and the decrease in light distribution to the right and left of the vertical center plane of the light distribution combined with the increase at the lateral outer edge of the light distribution ( Figure 11c ).

[0124] One aspect of the invention is the contour of the surface forming the film 24a, which is responsible for the realization of the traffic type of the optical solid body 10, and the reflection of light coupled into the optical solid body 10 occurs on this surface, not through the realization of the mold and through total internal reflection (TIR), but through the insertion of the structured film 24a or a film encapsulation comprising multiple films 24a, which may have a refractive index different from that of the transparent injection-molded material of the optical solid body 10, or may be metallized / mirrified to affect the incident light, in particular to reflect it.

[0125] One possible implementation for fabricating an optical solid body 10 with a structured, at least partially metallized film 24a includes the following steps:

[0126] A. Fabrication of structured membranes with three-dimensional shapes, configurations, and / or structures 24a (see...) Figure 12a );

[0127] B. Metallize at least one surface of the coupling input portion 16; 16a, 16b of the structured film 24a facing the optical solid body 10 with a metallization layer 24 (see...). Figure 12b );

[0128] as well as

[0129] C. The structured membrane 24a is inserted into the mold, and then at least one side of the membrane 24a is overlapped and injection molded using the transparent material 26 of the optical solid body 10 (see...). Figure 12c ).

[0130] D. Optionally, the opposite sides of the membrane 24a can also be injection molded in a separate working step using the transparent material 28 of the optical solid body 10 to achieve new functions, such as, for example, in DE.

[0131] As described in 10 2022 101 928A1 (see also) Figure 12d The transparent material 28 preferably has the same refractive index as the transparent material 26 on the opposite side of the film 24a.

[0132] One possible embodiment for manufacturing an optical solid body 10 with at least one structured film 24a includes the following steps: the structured film has a lower refractive index compared to the transparent injection-molded material of the optical solid body 10.

[0133] A. Fabricating at least one structured membrane 24a having a three-dimensional shape, configuration, and / or structure, wherein at least one membrane 24a is composed of a material or at least on the surface of the coupling portion 16, 16a, 16b of the structured membrane 24a facing the optical solid body 10, a layer having a lower refractive index than a transparent injection-molded material (see...). Figure 13a);

[0134] B. The structured film 24a is inserted into the mold, and then at least one side of the injection-molded film 24a is overlapped with the transparent material 26 of the optical solid body 10 (see...). Figure 13b ), and if necessary, insert and overlap injection mold another structured membrane 24a (if present).

[0135] C. Optionally, at least one opposite side of the film 24a may also be injection molded in a separate working step with an overlap of the transparent material 28 of the optical solid body 10 to achieve new functions, as described, for example, in DE 10 2022 101 928 A1 (not shown). The transparent material 28 preferably has the same refractive index as the transparent material 26 on the opposite side of at least one film 24a.

[0136] Figure 16a and Figure 16b Each shows an optical solid body 10 with an inserted film 24a, which is structured / metallized along / parallel to the optical axis 30, i.e., at the top and bottom of the film 24a. Figure 16a The metallization is shown in a side view, and Figure 16b Metallization is shown in a plan view.

[0137] Figure 17a and Figure 17b An example of how membrane 24a can be used to achieve a specific traffic type is shown, wherein target light reduction is achieved in the resulting low beam distribution (LB) of the light module 12 or lighting device 14. In this case, the target in membrane 24a is lowered, raised, or its angle is changed relative to the principal plane of the reflective surface of membrane 24a or the main surface range of membrane 24a (see [link]). Figure 17a This reduces the target luminous intensity in the area where legal measurement points can be achieved, for example, to avoid exceeding the maximum permissible luminous intensity.

[0138] exist Figure 17b In the example, absorption or scattering regions or partially absorbed (part of the incident light is absorbed and the other part is reflected) or partially scattered (part of the incident light is scattered and the other part is absorbed or reflected) regions are introduced into the membrane 24a in order to reduce the light intensity in the resulting light distribution or improve or increase the illumination in the top region.

[0139] Figures 18a to 18c This illustration shows an embodiment of the invention, in which the top region or high beam (HB) to low beam (LB) transition affects the resulting light distribution. A gap 48 in the film 24a allows light to enter areas that would otherwise not be illuminated or would be less intensely illuminated by the light function of the resulting light distribution. For example, Figure 18a and Figure 18bThis illustrates how light travels from the high beam range (HB) to the low beam range (LB). For this purpose, the gap 48, or the area of ​​the membrane 24a that defines or limits the gap 48, is designed in a specific manner such that light can only travel from HB to LB. This specific design includes, for example, an offset arrangement of the gap 48 in two membranes 24a that are introduced into the optical solid body 10 and extend parallel to each other (see [link to documentation]). Figure 18a ), or a gap 48 accessible only from one side (left side in the figure) in the membrane 24a introduced into the optical solid body 10 (see Figure 18b On the opposite side (on the right side of the diagram), the gap is shielded and access to gap 48 is not permitted.

[0140] Furthermore, it is conceivable, for example, in Figure 18a and Figure 18b In the opposite direction shown, light from the low beam (LB) reaches the high beam area (HB) above the light-dark boundary in order to achieve the required minimum luminous intensity over a large area or at a specific measurement point, for example, to meet legal requirements (see...). Figure 18c ).

[0141] Figure 19 An example of two films 24a metallized on both sides is shown, in which light propagates between the two films 24a along the direction of the light-dark boundary during the transition between the low beam (LB) and the high beam (HB).

[0142] As an alternative to metallization, Figure 19 In the example, a lower refractive index than that of the adjacent transparent materials 26, 28 of the optical solid body 10 can be provided on the upper side of the upper film 24a and the lower side of the lower film 24a.

[0143] at last, Figure 20a and Figure 20b An example is shown in which different Petzval adaptations of the optical solid body 10 or its coupled output portion 22 to the projection lens 40 can be achieved by using different films 24a, without the need to manufacture modified molds or mold inserts. This adaptation is achieved solely by using different films 24a, which differ from one another, particularly in the design of one of their edges, especially the front edge 58. This is also illustrated by the fact that... Figure 20a and Figure 20b In this case, the outer contour of the optical solid body 10 remains unchanged. The light distribution is altered only by introducing another optically active film 24a.

Claims

1. An optical solid body (10) made of a solid transparent material, the optical solid body being used in the optical module (12) of a motor vehicle lighting device (14), the optical solid body (10) comprising an optical coupling input portion (16) and an optical coupling output portion (22), wherein light from a light source (18) of the motor vehicle lighting device (14) can be coupled into the optical solid body (10) via the optical coupling input portion, and at least a portion of the light coupled into the optical solid body (10) is coupled into the optical solid body (10) via the optical coupling output portion. A portion of the light is coupled out from the optical solid body (10) such that the coupled-out light is used to generate at least a portion of the light distribution of the vehicle lighting device (14) in front of the vehicle, and the optical solid body (10) further includes an optically active layer (24) disposed in the beam path between the coupling input portion (16) and the coupling output portion (22), the layer being designed to modify the incident light, wherein the optically active layer (24) comprises at least one film (24a) and is disposed inside the optical solid body (10). Its features are, The at least one membrane (24a) has a three-dimensional shape, configuration and / or structure, and is injection molded on at least one of its surfaces by overlapping the transparent material of the optical solid body (10).

2. The optical solid body (10) according to claim 1, wherein the design of the three-dimensional shape, configuration and / or structure of the at least one film (24a) depends on the type of traffic for which the motor vehicle lighting device (14) including the optical module (12) with the optical solid body (10) is intended.

3. The optical solid body (10) according to claim 2, wherein the three-dimensional shape, configuration and / or structure is designed for one of the following traffic types or for achieving one of the following light functions: target reduction of luminous intensity in the area of ​​light distribution at right-hand traffic, left-hand traffic, legal measurement points, and target increase of luminous intensity in the area of ​​low beam light distribution above the horizontal light-dark boundary of the light distribution.

4. The optical solid body (10) according to any one of the preceding claims, wherein the at least one film (24a) having the three-dimensional shape, configuration and / or structure has a main surface range that, with respect to a motor vehicle lighting device (14) installed in a motor vehicle and having the optical module (12) having the optical solid body (10), extends substantially parallel to the lane in which the motor vehicle is parked or traveling.

5. The optical solid body (10) according to any one of the preceding claims, wherein the at least one film (24a) has inherent rigidity such that it maintains a designed three-dimensional shape, configuration and / or structure, the at least one film being incorporated into the designed three-dimensional shape, configuration and / or structure prior to being overmolded with the transparent material, and the designed three-dimensional shape, configuration and / or structure corresponding to the three-dimensional shape, configuration and / or structure of the overmolded film (24a) in the finished optical solid body (10).

6. The optical solid body (10) according to any one of the preceding claims, wherein the at least one film (24a) is designed as a reflective aperture, the reflective aperture defining the light and dark boundary of the low beam distribution of the vehicle lighting device (14) in front of the vehicle.

7. The optical solid body (10) according to claim 6, wherein the at least one film (24a) has a metallization layer on at least the surface facing the optical coupling input portion (16).

8. The optical solid body (10) according to any one of claims 1 to 5, wherein the at least one film (24a) has a lower refractive index than the transparent material of the optical solid body (10) used for overmolding the at least one film (24a).

9. The optical solid body (10) according to claim 8, wherein the at least one film (24a) has a layer on the surface facing the optical coupling input portion (16) having a refractive index lower than that of the transparent material of the optical solid body (10) for overlay injection molding of the at least one film (24a).

10. An optical solid body (10) according to any one of the preceding claims, wherein the at least one film (24a) is designed to completely or partially convert light of a first spectrum coupled into the optical solid body (10) into light of another spectrum.

11. A method for manufacturing an optical solid body (10) from a solid transparent material, said optical solid body being used in an optical module (12) of a motor vehicle lighting device (14) according to any one of the preceding claims, Its features Steps - Provide a membrane (24a) with a defined three-dimensional shape, configuration and / or structure. - Coating at least the first surface of the film (24a), - Insert the membrane (24a) into the mold, and - The first surface of the film (24a) is injection molded into the transparent material of the optical solid body (10).

12. The method of claim 11, wherein the first surface of the film (24a) is coated with a metallization layer and / or has a layer with a refractive index lower than that of the transparent material used for overlay injection molding of the at least one film (24a).

13. The method according to claim 11 or 12, wherein after the first surface of the inserted film (24a) has been overmolded with the transparent material of the optical solid body (10), the relatively positioned second surface of the inserted film (24a) is also overmolded with the transparent material of the optical solid body (10).

14. The method according to any one of claims 11 to 13, wherein an additional membrane (24a) having a three-dimensional shape, configuration and / or structure is placed in the mold on the overlapping injection-molded transparent material of the optical solid body (10), and is overlapping injection-molded with the transparent material of the optical solid body (10) on at least one of its surfaces.

15. The method according to any one of claims 11 to 14, wherein the three-dimensional shape, configuration and / or structure of the membrane (24a) is defined according to the traffic type for which the motor vehicle lighting device (14) having the optical module (12) with the optical solid body (10) is intended, and is defined or defined for achieving one of the following lighting functions: right-hand traffic, left-hand traffic, a target reduction in luminous intensity in the area of ​​the light distribution at the legal measurement point, and a target increase in luminous intensity in the area of ​​the low beam light distribution above the horizontal light-dark boundary of the light distribution.

16. A light module (12) for a motor vehicle lighting device (14), the light module comprising a light source (18) and an optical solid body (10), wherein the light source (18) is designed and arranged and aligned relative to the optical solid body (10) such that it emits light in a main emission direction in the direction of a light coupling input portion (16) of the optical solid body (10), and wherein the optical solid body (10) is designed to use an optically active layer (24) comprising at least one film (24a) to modify the light coupled into the optical solid body (10) via the coupling input portion (16), at least a portion of the coupled-input light irradiating the at least one film, such that light coupled out via a coupling output portion (22) of the optical solid body (10) generates at least a portion of the light distribution of the motor vehicle lighting device (14) in front of the motor vehicle, characterized in that, The optical solid body (10) is designed according to one of claims 1 to 10.

17. The optical module (12) according to claim 16, wherein the optical module (12) has a plurality of light sources (18) and / or a plurality of solid optical bodies (10).

18. The optical module (12) according to claim 16 or 17, wherein the optical module (12) has a projection lens (40) arranged downstream of the coupling output portion (22) of the optical solid body (10) in the beam path and designed to image an intermediate image formed in an intermediate image plane (60) as the light distribution of the motor vehicle lighting device (14) or as part of the light distribution in front of the motor vehicle, the intermediate image plane preferably being arranged in the optical solid body (10).

19. A lighting device (14) for a motor vehicle, the lighting device having a housing (34) and at least one optical module (12) located inside the housing (34), the housing having a light emission opening (36) closed by a cover plate (38), the at least one optical module projecting light in front of the motor vehicle to generate a light distribution or a portion thereof of the lighting device (14). Its features are, The at least one optical module (12) is designed according to one of claims 16 to 18.

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