Lighting device, motor vehicle, mounting method

Abstract

The invention relates to a lighting device (10) for a motor vehicle (18), wherein the lighting device (10) can be mounted on the motor vehicle (18) along a mounting direction (20), comprising: a cover disk (12) having a fastening section (38) and a sealing section (40); a sealingly closed element (14) arranged on the sealing section (40), wherein the closed element (14) and the cover disk (12) delimit a cavity (26); a light module (16) for generating light arranged in the cavity (26), the light module (16) having at least one light source (30) and a carrier element (34) carrying the at least one light source (30), wherein the light module (16) is arranged on the fastening section (38) by means of the carrier element (34), wherein the closed element (14) is configured as a film.

Description

Technical Field

[0001] This invention relates to a lighting device and an installation method. Background Technology

[0002] A lighting device having a cover plate and a structural element carrying an optical module is known from DE202011100750U1, wherein the structural element seals the opening of the cover plate in a sealed manner. Sealing the opening with the structural element is particularly disadvantageous in repair situations because the structural element must be cut off to open it and then re-secured and sealed with additional components.

[0003] An optical unit having an optical housing and a cover element is known from DE102019218671A1, wherein a thin film is provided on the outer layer of the cover element as a protective device. An illumination device having a fastening element in the form of a retaining clamp is known from DE202010003680U1. An illumination device having a light-transmitting area and a light-blocking area is known from DE102023100627A1, wherein the light-blocking area is provided by a thin film injected into a closing disc. An illumination device having a clamping element for holding a cable is known from DE102009018445A1. Summary of the Invention

[0004] The purpose of this invention is to provide a lighting device that is easy to repair and reduces the need for repairs.

[0005] The objective of this invention is achieved through a lighting device having the features of this invention. This invention relates to a lighting device for motor vehicles, wherein the lighting device can be mounted on the motor vehicle along an installation direction, and in particular, can be incorporated into the motor vehicle. The lighting device includes: a cover plate having a fastening section and a sealing section; a sealing element disposed on the sealing section, wherein the sealing element and the cover plate define a cavity; a light module for generating light disposed in the cavity, the light module having at least one light source and a carrier element carrying the at least one light source, wherein the light module is disposed on the fastening section by means of the carrier element; wherein the sealing element is configured as a film or potting material.

[0006] Therefore, the membrane can be easily detached during repairs to provide a cavity for the cover plate and access to the optical module. A new membrane can then be installed on the sealing section. Using a membrane as a sealing element is possible because the sealing element is sealed but does not absorb mechanical loads. Using a membrane as a sealing element also reduces weight, cost, and CO2. The membrane can be detached from the cover plate, simplifying recycling. Furthermore, the lighting device according to the invention saves structural space. An additional seal between the cover plate and the sealing element is eliminated.

[0007] For the purposes of this invention, "thin film" can be understood as a thin, uniform planar configuration.

[0008] The film is preferably constructed to be flexible. The film has a first stiffness. The carrier element has a second stiffness. The first stiffness is preferably configured to be lower than the second stiffness. The film preferably has a thickness between 0.01 mm and 5 mm, particularly between 0.05 mm and 3 mm, and preferably between 0.1 mm and 1 mm. The film is preferably constructed as one, two, or multiple layers. The film is preferably made of one, two, or more materials, particularly PC or PET, or a pre-coated film.

[0009] The thin film is preferably processed in such a way that air exchange between the cavity and the environment is possible. The thin film can be, for example, perforated, especially laser-perforated. Alternatively, Gore-Tex films are conceivable for use with the thin film.

[0010] The lighting system preferably comprises headlights, separate daytime running lights, turn signals, a small projector, taillights, and / or light strips. The cover plate is preferably manufactured using an injection molding method.

[0011] As an alternative to a film, the opening can be sealed by introducing a sealing potting material, particularly a sealant and / or sealing adhesive, preferably a two-component adhesive, into the opening. The potting material, particularly the sealant and / or adhesive, can be configured such that it can be peeled off as a single piece after curing. Therefore, sustainable repair can be further achieved. Furthermore, the potting material can be configured in terms of material selection and / or composition such that the adhesion of the potting material varies locally, thus preventing undesirable detachment, but simultaneously allowing targeted detachment at a specific location, particularly with the aid of a release liner. In this case, the potting material, particularly the adhesive film, can then be peeled off for repair purposes. This results in a particularly advantageous solution.

[0012] The potting material is preferably applied to the sealing section and / or the inside of the cover plate and / or especially to the optical module against the cover plate.

[0013] An advantageous aspect of the invention is that the enclosure element and the carrier element are configured separately and / or spaced apart from each other. Therefore, the enclosure element and the carrier element can be configured differently. Since the carrier element carries the printed circuit board with LEDs, it is rigidly configured. Because the enclosure element is sealed, rigid and heavy-duty components are not required.

[0014] An advantageous aspect of the invention is that the sealing element and the carrier element are not directly and effectively connected to each other. Therefore, it is ensured that the sealing element does not absorb mechanical loads.

[0015] Alternatively, it is conceivable that the carrier element is potted with a potting material.

[0016] An advantageous aspect of the invention is that the cover disc has at least one disc sheath extending parallel to the mounting direction, and the disc sheath protrudes relative to the carrier element parallel to the mounting direction.

[0017] An advantageous aspect of the invention is that the sealing section is arranged on the disk sheath, particularly on at least one free end of the disk sheath that is oriented in the mounting direction. Therefore, the sealing elements can be securely and spaced apart on the cover disk, and the cavity of the cover disk forms sufficient space for housing the optical module.

[0018] The sealing section is preferably configured to extend within a plane. Alternatively, the sealing section is configured to at least partially deviate from a plane. The edge surfaces of the sealing section may also at least segmentally follow the concave or convex cylindrical sheath and / or the concave or convex conical sheath.

[0019] An advantageous aspect of the invention is that the cover disc has a front side that rotates against the installation direction, and the fastening section is arranged on the disc sleeve and / or on the front side. Advantageously, the fastening section and the sealing section are configured individually and / or spaced apart from each other. Therefore, it is further ensured that the sealing element does not have to absorb mechanical loads.

[0020] An advantageous aspect of the invention is that the sealing section and the sealing element are connected to each other in a sealing manner by means of welding, especially laser welding, adhesive bonding, and / or hot stamping. This ensures a reliable seal of the cavity. The sealing section and the sealing element are preferably connected to each other in a watertight manner about the mounting direction. In the case of welding, contour welding, simultaneous welding, friction welding, and / or vibration friction welding methods are conceivable.

[0021] An advantageous aspect of the invention is that a clamping element for clamping the sealing section and the sealing element is additionally arranged on the sealing section. The clamping element can preferably be connected to, and in particular screwed onto, the sealing section. In the installed state, the sealing element is arranged between the clamping element and the sealing section.

[0022] An advantageous aspect of the invention provides a support element for supporting the sealing element against the installation direction. The sealing element preferably rests against the support element in the installed state. Therefore, vibration of the membrane, for example, during operation can be avoided, which can reduce noise. The support element is preferably arranged between the carrier element and the sealing element. The support element is preferably connected to the cover plate on the fastening section. For the sealing element to be advantageously rested on the support element, the surface of the support element facing the sealing element and the surface of the sealing section facing the sealing element lie in a plane extending perpendicular to the installation direction. In this case, for example, a welding device can establish the connection between the sealing element and the sealing section and the support element.

[0023] The support element is preferably also configured as a membrane, particularly as the same membrane as the closure element. Alternatively, the support element may be configured to be more rigid than the membrane in order to increase the rigidity of the cover plate that opens along the mounting direction.

[0024] An advantageous aspect of the invention provides a connecting element, particularly a plug, for electrical contact with a motor vehicle. The connecting element is preferably arranged on a disc sheath. Here, the connecting element extends perpendicularly to the mounting direction through the cover disc, particularly the disc sheath. Alternatively, a sealing element extends parallel to the mounting direction, particularly extending through the sealing element. In this case, it is particularly advantageous that the supporting element and the sealing element abut against each other, particularly around the connecting element. This provides a seal in the area of ​​the connecting element. This area is preferably bonded together. The connecting element is preferably configured to be integrated into the cover disc. This can be achieved by inserting the connecting element into the mold prior to the injection molding process used to manufacture the cover disc.

[0025] An advantageous aspect of the invention specifies that the cover disc is configured as a single part, a two-part part, or a multi-part part. When the cover disc is configured as a two-part or multi-part part, at least one first component section forms the front side, and at least one second component section, separately configured for this purpose, forms the disc sheath, particularly a sealing section. The second component section may have higher rigidity than the first component section in order to provide stable attachment to the motor vehicle when a flange section is provided in this area.

[0026] An advantageous aspect of the invention is that the cover disc has a flange section in the sealing section area, particularly on the disc sleeve, for securing the lighting device to the motor vehicle, and which projects outward, particularly perpendicular to the mounting direction, and / or rotates around the mounting direction. In the case of a two-part or multi-part structure of the cover disc, the flange section is preferably arranged on at least one second component section.

[0027] An advantageous aspect of the invention provides that the cover disc has a stop section in the area of ​​the sealing section, particularly on the disc sleeve, that protrudes particularly in the mounting direction and / or rotates around the mounting direction, as a splash-proof device for the sealing element, particularly the connection between the sealing element and the cover disc.

[0028] The objective of this invention is also achieved by a method having the features of this invention. This invention relates to a method for installing a previously described lighting device. The method includes the following steps, particularly in the order mentioned: providing a cover plate; inserting an optical module into a cavity of the cover plate; attaching the optical module to a fastening section of the cover plate by means of a carrier element; and fastening a sealing element in the form of a thin film to a sealing section of the cover plate for sealing the cavity and the optical module.

[0029] An advantageous aspect of the invention is that the fastening is performed by means of welding, particularly laser welding, bonding, and / or hot stamping. In the case of welded joints, contour welding, simultaneous welding, friction welding, and / or vibration friction welding methods are conceivable. Attached Figure Description

[0030] Further advantages, features, and details will arise from the following description, in which various embodiments of the invention are illustrated with reference to the accompanying drawings. Here, features mentioned in the claims and description, whether individually or in any combination, are essential to the invention. In the drawings: Figures 1 to 3 Each illustrates an embodiment of the lighting device according to the present invention. Detailed Implementation

[0031] according to Figures 1 to 3 The lighting device 10 has a cover plate 12, a closure element 14, and a light module 16. The lighting device 10 can be installed on a motor vehicle 18 by being guided along the installation direction 20.

[0032] The cover plate 12 has a front side 22 facing away from the mounting direction 20 and a plate sleeve 24 extending parallel to the mounting direction 20. The front side 22 defines a cavity 26 against the mounting direction 20, and the plate sleeve 24 defines the cavity 26 perpendicular to the mounting direction 20, the cavity 26 ending at an opening 28.

[0033] The optical module 16 can be inserted into the cavity 26. The optical module 16 has at least one light source 30, particularly at least one LED, a printed circuit board 32 (PCBA) housing the at least one light source 30, and a carrier element 34 holding the at least one light source 30 and the printed circuit board 32. The printed circuit board 32 is connected to the carrier element 34 by means of hot stamping, clamping, and / or spiral devices 36. The carrier element 34 is connected to a fastening section 38 of the cover plate 12 by means of the spiral devices 36. The fastening section 38 is preferably arranged on the front side 22. In the installed state, the optical module 16 is fully disposed in the cavity 26 such that the cover plate 12 protrudes relative to the optical module 16 along the mounting direction 20. Therefore, the optical module 16 does not protrude from the opening 28. The optical module 16 may also have additional optical components, which are also disposed in the cavity 26. Additional mechanical, electronic, and / or optical technology components and / or design elements may also be disposed in the cavity 26.

[0034] The opening 28 is closed by means of a closure element 14 in the form of a thin film, such that the cavity 26 is defined by the closure element 14 along the mounting direction 20. The closure element 14 is fastened to the sealing section 40 of the cover plate 12, particularly the plate sheath 24, in the installed state. The sealing section 40 is preferably arranged on the free end 42 of the cover plate 12 along the mounting direction 20. The closure element 14 is arranged around the sealing section 40 in such a rotatable manner about the mounting direction 20 that the cavity 26 is sealed and the optical module 16 is protected. The fastening section 38 is preferably arranged spaced apart from the sealing section 40. The optical module 16 is arranged on the cover plate 12, particularly on the fastening section 38, such that the closure element 14 and the optical module 16 are spaced apart from each other. The optical module 16 is preferably arranged between the fastening section 38 and the sealing section 40 and / or the closure element 14 along the mounting direction 20.

[0035] In a preferred embodiment, the sealing segment 40 is configured to extend within a plane. In another preferred embodiment, the sealing segment 40 may at least partially deviate from a plane. The edge surfaces of the sealing segment 40 may also at least segmentally follow concave or convex cylindrical sheaths and / or concave or convex conical sheaths. In the aforementioned cases, the sealing element 14, in particular the film, can be applied to the edge without creases. It is particularly advantageous that the sealing element 14, in particular the film, rests completely and without creases on the edge. The edge surfaces of the sealing segment 40 ensure this.

[0036] The film of the sealing element 14 and / or the support element 56 preferably has a film thickness in the range of 0.01 mm to 5 mm, especially between 0.05 mm and 3 mm, and preferably between 0.1 mm and 1 mm.

[0037] The closure element 14 and the cover plate 12 can preferably be connected to each other in a rotatable, sealed manner by means of welding, especially laser welding, adhesive bonding, and / or hot stamping. In the case of welding, contour welding, simultaneous welding, friction welding, and / or vibration friction welding methods are conceivable.

[0038] The enclosure element 14 and the optical module 16, especially the carrier element 34, are configured separately and spaced apart from each other. Furthermore, the enclosure element 14 and the carrier element 34 are not directly and effectively connected to each other, even though both are connected to the cover plate 12. Therefore, no mechanical load is discharged through the enclosure element 14.

[0039] according to Figures 1 to 3 The sealing element 14 can be additionally clamped or pressed against the sealing section 40 by the clamping element 44. This further ensures a strong and tight fastening between the cover plate 12 and the sealing element 14. The clamping element 44 can be screwed onto the sealing section 40 by means of a screw device 36.

[0040] according to Figures 1 to 3 The cover plate 12 has a flange section 46 on its free end 42 in the area of ​​the sealing section 40, which protrudes outward relative to the sealing section 40 perpendicular to the mounting direction 20. The lighting device 10 is fastened to the motor vehicle 18 by means of the flange section 46. The motor vehicle 18 is in Figure 1 As shown in the image.

[0041] according to Figure 1 The cover plate 12 also has a stop section 48 protruding relative to the sealing section 40 on the plate sleeve 24 in the region of the sealing section 40, along the mounting direction 20, as a splash-proof device for the connection between the sealing element 14, especially the connection between the sealing element 14 and the cover plate 12. The stop section 48 may also be provided. Figure 2 and Figure 3 middle.

[0042] exist Figure 1 In the diagram, the cover plate 12 is shown by dashed line 50 as potentially being configured as a two-part structure. In this two-part configuration, the cover plate 12 has a first component section 52 and at least one second component section 54 configured separately for this purpose. In this case, a fastening section 38 and a front side 22 are arranged in the first component section 52, and / or a sealing section 40 and / or a flange section 46 and / or a stop section 48 are arranged in the second component section 54. Since the mechanical load is transmitted to the motor vehicle 18 through the second component section 54 in this configuration, it is advantageous that the second component section 54 is configured to be more rigid and / or more robust than the first component section 52. Therefore, a more durable lighting device 10 can be provided. Alternatively, the second component section 54 may have a fastening section 38 and a flange section 46.

[0043] In addition, product markings, especially in the form of labels, engravings and / or engravings, can be provided on the cover plate 12 for the lighting device 10.

[0044] according to Figure 3 The lighting device 10 has a support element 56 for supporting the closure element 14 against the installation direction 20. The closure element 14, in the installed state, preferably abuts against the support element 56 in sections. Therefore, vibration of the closure element 14, especially the film, can be avoided, for example, during operation, thereby reducing noise. The support element 56 is preferably arranged between the carrier element 34 and the closure element 14. The support element 56 is preferably connected to the cover plate 12 at a fastening section 38. The support element 56 is also preferably configured as a film. The support element 56 substantially abuts against the optical module 16. The support element 56 and the closure element 14 can be connected to each other, at least in sections, especially by adhesive.

[0045] according to Figure 2 and Figure 3 The lighting device 10 has a connection element 58 in the form of a plug for electrical contact with the motor vehicle 18. According to... Figure 2 A connecting element 58 is arranged on the disc sleeve 24. Here, the connecting element 58 extends perpendicularly to the mounting direction 20 through the cover disc 12, and in particular the disc sleeve 24. The connecting element 58 is preferably configured to be integrated into the cover disc 12. This can be achieved by inserting the connecting element 58 into the mold prior to the injection molding process used to manufacture the cover disc 12. Figure 3 The closure element 14 extends parallel to the mounting direction 20, and in particular extends through the closure element 14. This is advantageous because the plug can be connected in the same manner along the mounting direction 20 when inserted into the motor vehicle 18. In this case, it is particularly advantageous that the support element 56 and the closure element 14 abut against each other, especially around the connecting element 58. Thus, a seal is provided in the area of ​​the connecting element 58. This area is preferably bonded to each other.

Claims

1. A lighting device (10) for a motor vehicle (18), wherein, The lighting device (10) can be mounted on the motor vehicle (18) along the mounting direction (20), and the lighting device (10) includes: - A cover plate (12) having a fastening section (38) and a sealing section (40); - A sealing element (14) arranged on the sealing section (40), wherein the sealing element (14) and the cover plate (12) define a cavity (26). - An optical module (16) for generating light is arranged in the cavity (26), the optical module (16) having at least one light source (30) and a carrier element (34) carrying the at least one light source (30), wherein the optical module (16) is arranged on the fastening section (38) by means of the carrier element (34); The sealing element (14) is configured as a thin film or potting material.

2. The lighting device (10) according to claim 1, wherein, The closure element (14) and the carrier element (34) are configured individually and / or spaced apart from each other.

3. The lighting device (10) according to claim 1 or 2, wherein, The enclosing element (14) and the carrier element (34) are not directly and effectively connected to each other.

4. The lighting device (10) according to any one of the preceding claims, wherein, The cover plate (12) has at least one plate sleeve (24) extending parallel to the mounting direction (20), and wherein the plate sleeve (24) protrudes relative to the carrier element (34) parallel to the mounting direction (20).

5. The lighting device (10) according to claim 4, wherein, The sealing section (40) is arranged on the disc sleeve (24), especially on at least one free end (42) of the disc sleeve (24) that is turned in the installation direction (20).

6. The lighting device (10) according to any one of the preceding claims, wherein, The cover plate (12) has a front side (22) that is turned in the opposite direction of the installation direction (20), and wherein the fastening section (38) is arranged on the plate sleeve (24) and / or on the front side (22).

7. The lighting device (10) according to any one of the preceding claims, wherein, The sealing section (40) and the sealing element (14) are connected to each other in a sealed manner by means of welding, especially laser welding, adhesive bonding and / or hot stamping.

8. The lighting device (10) according to claim 7, wherein, A clamping element (44) for clamping the sealing section (40) and the closing element (14) is additionally arranged on the sealing section (40).

9. The lighting device (10) according to any one of the preceding claims, wherein, A support element (56) is provided for supporting the closure element (14) in the opposite direction of the installation (20).

10. The lighting device (10) according to any one of the preceding claims, wherein, A connecting element (58), particularly a plug, is provided for electrical contact with the motor vehicle (18), wherein the connecting element (58) is arranged on the disc sheath (24) or extends through the closure element (14).

11. The lighting device (10) according to any one of the preceding claims, wherein, The cover plate (12) is configured as a single part, a two-part part, or a multi-part part.

12. The lighting device (10) according to any one of the preceding claims, wherein, The cover plate (12) has a flange section (46) in the area of ​​the sealing section (40) for fastening the lighting device (10) to the motor vehicle (18).

13. The lighting device (10) according to any one of the preceding claims, wherein, The cover plate (12) has a stop section (48) in the area of ​​the sealing section (40) as a splash-proof device for the connection between the sealing element (14), especially the connection between the sealing element (14) and the cover plate (12).

14. A motor vehicle (18) having a lighting device (10) according to any one of the preceding claims.

15. A method for installing a lighting device (10) according to any one of claims 1 to 13, comprising the following steps: a) Provide the cover plate (12); b) Insert the optical module (16) into the cavity (26) of the cover plate (12); c) The optical module (16) is connected to the fastening section (38) of the cover plate (12) by means of the carrier element (34); as well as d) Secure the sealing element (14) in the form of a film or potting material to the sealing section (40) of the cover plate (12) for sealing the cavity (26) and the optical module (16).

16. The method according to claim 15, wherein, The fastening is achieved by means of welding, especially laser welding, bonding and / or hot stamping.

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