Lighting device for a vehicle and manufacturing method

Abstract

The invention relates to a lighting device for a vehicle, having a shell-shaped housing (1) in which a number of optical components are arranged for producing one or more light functions with a predefined light distribution, wherein the housing (1) has a base (2) and a wall (3) projecting from the base (2), which wall has an opening edge (9) and an edge ridge (8) of the opening edge (9), which defines an opening of the housing (1), and the lighting device has a cover panel (4) fixedly connected with the housing (1) in the region of the edge ridge (8) of the opening edge (9), wherein the cover panel is configured as a printable cover film (4) which is connected with force-locking to the opening edge (9) of the housing (1) with a surrounding edge flange (7).

Description

Technical Field

[0001] The present invention relates to a lighting device for a vehicle having a shell-shaped housing in which a number of optical components are arranged for generating one or more light functions having a predetermined light distribution, wherein the housing has a bottom and a wall protruding from the bottom, the wall having an opening edge and an edge ridge of the opening edge defining an opening of the housing, and the lighting device having a cover plate fixedly connected to the housing in the region of the edge ridge of the opening edge.

[0002] The present invention also relates to a method for manufacturing a cover film according to claim 13. Background Technology

[0003] A lighting device for a vehicle is known from DE102016123203B4. This device has a shell-shaped housing in which multiple optical structural elements, such as light sources and optics, such as reflectors or light conductors, are arranged. The housing has a bottom and a wall projecting from the bottom, the wall forming an open edge with edge ridges at its free end. To cover this open edge, a cover plate is provided, which is connected to the open edge of the housing by laser welding. The cover plate has a light-transmitting main section and opaque, preferably black, blocking sections on the edge sides. Through the opaque blocking sections, the weld is not visible to an observer from the outside. When the cover plate is manufactured using a two-component injection molding method, the manufacturing cost for the cover plate is relatively high. A relatively large mold half is required. Furthermore, a relatively high material usage is required because the wall thickness of such a cover plate is in the range of 2 mm to 4 mm. Additionally, the recycling of pure species or pure materials is relatively costly. Summary of the Invention

[0004] Therefore, the object of the present invention is to provide a lighting device for a vehicle and a method for manufacturing a cover plate, so as to provide an attractive appearance of the lighting device in a manner that is simple in manufacturing technology and cost-effective.

[0005] To address this task, the present invention, in conjunction with the preamble of claim 1, features that the cover plate is constructed as a printable cover film, the cover film being force-locked to the opening edge of the housing by a surrounding edge flange.

[0006] According to the invention, the cover plate is constructed as a cover film, which is force-locked to the housing of the lighting device at its edge side. For this purpose, the cover film has a surrounding edge flange, which preferably abuts against the outer side of the opening edge of the housing in a planar manner. Thus, the cover film surrounds the opening of the housing or the edge of the opening and is arranged overlapping and / or lapping against the opening edge. Here, the edge edge of the opening is completely covered. Advantageously, unwanted deposits, such as moss, dust, or the like, will not accumulate in the area of ​​the edge edge of the opening edge. Because the end of the edge side of the cover film has a predetermined minimum distance from the edge edge of the opening edge, any dirt deposits will move further away from the opening edge, more specifically, towards the bottom of the housing. Since the cover plate is constructed as a cover film, it can be formed into a predetermined shape by a thermoforming process, in which the surrounding edge flange abuts against the housing in a planar and sealing manner on the outside. If, for example, an opaque blocking section should be provided in the edge region, this blocking section can be simply manufactured by printing. Alternatively, transparent or opaque graphics or color gradients can be integrated through printing, allowing the cover film to have a clean, independent appearance.

[0007] According to an improved embodiment of the invention, the edge flange of the covering film is secured to the outside of the opening edge of the housing in the assembled position by means of a surrounding clamping element. The subsequent separation of the components of the lighting device, used for the recycling of pure species or pure materials, is simplified by the clamping or force-locking connection structure.

[0008] According to an improved embodiment of the invention, the clamping element has a retaining strap of a predetermined width that rests against the outer side of the opening edge, and a strap fixing member for tensioning the retaining strap, such that the predetermined tension or fixing force is adjustable. Alternatively or additionally, the clamping element may be configured to secure the covering film to the housing in a detachable manner, so that the lighting device can also be opened from the front side of the lighting device.

[0009] According to an improved embodiment of the invention, the fixing strap is made of a metal or textile material, which surrounds the edge flange of the cover film, preferably made of a plastic material, and the opening edge of the housing.

[0010] According to an improvement of the invention, the opening edge of the housing is configured to arch outward, such that the retaining strap rests uninterruptedly against the outer side of the opening edge in the assembled position. Therefore, the housing must always have an outward arch that prevents the retaining strap from losing contact with the housing and thus eliminates any seal in such inwardly arched areas of the housing.

[0011] According to an improved embodiment of the invention, a sealing strip is provided between the fixing band of the clamping element and the opening edge of the housing, thereby forming a defined contact surface for the fixing band. For example, when the edge edge of the opening has an outwardly protruding tab, this can also compensate for thickness differences in the opening edge region.

[0012] According to an improved embodiment of the invention, the sealing strip can be bonded to the opening edge of the housing and, if necessary, also to the inner side of the edge flange of the cover film. Thus, the cover film can be easily positioned in the assembly position for subsequent final fixation by installing clamping elements.

[0013] According to an improved embodiment of the invention, the cover film has an opaque main section and surrounding edge shielding sections, wherein the shielding sections have an opaque printed layer. This printed layer can therefore be achieved by printing an opaque dye.

[0014] To solve the aforementioned task, the present invention provides an assembly method according to claim 13.

[0015] Advantageously, in the first method step, the cover plate is placed in an assembly position in which its edge flange covers the opening edge of the housing. In the second step, it can now be secured in this assembly position by means of a clamping element, wherein the edge flange of the cover plate is tensioned to the opening edge of the housing. The cover plate can be positioned in a defined assembly position relative to the housing by means of the cover plate's shape having an circumferential edge flange that extends at an angle relative to the main section of the cover plate. Force-locking fixation can then be performed.

[0016] According to an improvement of the method, a sealing strip is pre-applied to the opening edge of the housing, preferably adhesively connected to the opening edge. This compensates for height differences at the opening edges, ensuring planar contact when the edge flange is subsequently abutted against the outside of the sealing strip, or ensuring that the edge flange adheres securely to the sealing strip and thus to the opening edge of the housing if the sealing strip has an additional adhesive outer surface. Final fixation is then achieved by force-locking application using clamping elements.

[0017] To address the present invention, a method for manufacturing according to claim 15 is provided.

[0018] Advantageously, color and / or structural and / or decorative and / or optical microstructures can be printed on the masking film while it is in a flat state. The printed masking film can then be formed in a thermoforming mold under heat and / or pressure, wherein the main sections are substantially constructed to be flat or slightly arched and the edge flanges extend from the main sections at a predetermined angle. If the masking film is fed to the forming mold on a roll rather than in sheet form, the individual masking films are finally separated from each other in sequence by a separating tool. Advantageously, this allows for the simple manufacture of masking films having a predetermined three-dimensional shape and, if necessary, optical or graphic structures. Attached Figure Description

[0019] The embodiments of the present invention are described in more detail below with the aid of the accompanying drawings.

[0020] In the attached diagram:

[0021] Figure 1 The image shows a front view of a lighting device having a covering film that obscures an opening in the device's housing.

[0022] Figure 2 A horizontal sectional view of a lighting device is shown, the device having a surrounding fixing band shown in dashed lines.

[0023] Figure 3 A horizontal sectional view of the lighting device housing is shown after the sealing tape has been applied to the outside of the opening edge of the housing.

[0024] Figure 4 This shows a horizontal sectional view of the housing in its assembled position on the housing before being secured by clamping elements. Detailed Implementation

[0025] Lighting devices for vehicles can be configured as headlights, for example, arranged in the front region of the vehicle. Alternatively, the lighting device can also be arranged as taillights in the rear region of the vehicle.

[0026] The lighting device has a shell-shaped housing 1, which has a bottom 2 and a surrounding wall 3 extending from the bottom at an angle. The wall 3 has a height such that a light source (preferably not shown) and optical light-shaping devices (optical components), such as reflectors and / or light conductors and / or lenses, are located within the housing 1. The optical light-shaping devices are configured such that they deflect the light generated by the light source according to a pre-defined light distribution, such as a near beam distribution and / or a far beam distribution.

[0027] To cover the opening of the housing 1, a cover plate 4 configured as a cover film is provided. The cover plate has a light-transmitting main section 5 and an edge section 6 surrounding the main section 5. The edge section 6 can, for example, be configured as an opaque blocking section. The blocking section 6 can, for example, be implemented as black, so that the edge of the cover film 4 also forms the optical edge of the cover film 4 when viewed from the outside. The main section 5 can, for example, be configured to be glass-like transparent, or in the taillight, it can have a predetermined color, such as red.

[0028] Edge segment 6 has a surrounding edge flange 7 that extends from main segment 5 at a predetermined angle α relative to main segment 5. (As shown by...) Figure 2 and Figure 4 As can be seen, the main section 5 of the covering film 4 extends substantially in the plane opened by the edge ridge 8 of the opening edge 9 of the wall 3, wherein the opening of the housing 1 is substantially covered. The edge flange 7 of the covering film 4 extends at an acute angle α or a right angle to the main section 5, wherein the edge flange has a width b. R This allows it to cover or cover the width b of the sealing strip 10 applied to the opening edge 9. D .

[0029] The sealing tape 10 is preferably applied adhesively to the outer side 11 of the opening edge 9. If the outer side of the sealing tape 10 facing the edge flange 7 also has an adhesive surface, then the masking film 4 can be placed according to the sealing tape 10 by adhesively attaching the edge flange 7 to it. Figure 4 In the assembly position.

[0030] As by Figure 3 As can be seen, a sealing strip 10, for example made of a flexible and / or elastic material, is applied to the outer side 11 of the opening edge 9, whereby it stops against an edge tab 12 extending outward from the opening edge 9, the edge tab being located on the edge ridge 8 of the opening edge 9. Preferably, the wall thickness w of the sealing strip 10 is... D The height h is greater than the edge patch height 12 R This causes the edge flange 7 of the covering film 4 to be in a planar position against the sealing strip 10.

[0031] The sealing strip 10 is arranged continuously around the opening edge 9 of the housing 1 and thus forms a frame-like receiving portion for covering the edge flange 7 of the membrane 4.

[0032] If, according to an alternative embodiment of the invention (not shown), the opening edge 9 does not have a protruding edge tab 12, but instead has a continuous flat outer side 11, then on the one hand, the sealing strip 10 can be omitted, so that the edge flange 7 can directly abut against the outer side 11 of the opening edge 9, and / or, in the presence of the sealing strip 10, the sealing strip can extend directly to the edge ridge 8 on the end side of the housing 1.

[0033] To ensure that the cover film 4 is forcefully locked to the housing 1 in its assembled state, a clamping element 12 is provided. This clamping element has a surrounding fixing band 14 that abuts against the outer side 11 of the cover film 4, and a fixing adjustment member 15 for tensioning the fixing band 14. (See also...) Figure 2 The dashed line in the middle.

[0034] The fixing strap 14 can be made of, for example, metal or textile materials.

[0035] The fixing adjustment component 15 can be configured as a tension adjustment device that, by manual operation or by means of a tool, tightens the fixing band 14 to apply a tension force F perpendicularly to the edge flange 7 or the sealing band 10 or the opening edge 9 of the housing 1. This tension force F acts around the opening edge 9 of the housing 1, more precisely, always in a direction normal to the edge flange 7 or the opening edge 9. To apply the circumferential tension force F, the wall 3 of the housing 1 must be formed such that there is no inward arching. Figure 1 As can be seen, only the first wall section 3' that curves outward or the flat wall section 3 is permitted.

[0036] Before the clamping element 13 abuts against the outer side 11 of the edge flange 7, the length l of the fixing strap 14 is... B The length l is greater than the opening edge 9. R As the clamping element 13 is manipulated, the fixing band 14 is gradually tightened, causing the length l of the fixing band 14 to increase. B The length l corresponds to or is slightly smaller than the edge of the opening. R This generates a tension force F, which presses the edge flange 7 against the opening edge 9. This eliminates unwanted relative movement between the edge flange 7 and the opening edge 9 or the sealing strip 10 in the plane of the attachment or contact surface.

[0037] The masking film 4 is made of plastic material, especially transparent plastic material, such as PMMA. The masking film 4 may have a wall thickness w that is preferably constant in the range of 0.5 mm to 1.5 mm, and more preferably in the range of 0.75 mm to 1.25 mm. A The covering membrane 4 is constructed to be resistant to bending.

[0038] In this embodiment, the edge segment 6 is configured as an opaque segment, which is constructed to be opaque. The opaque segment 6 surrounds the edge 8 of the housing 1, such that the end side or edge 8 of the wall 3 of the housing 1 is covered from the outside and therefore invisible to the observer.

[0039] The shielding section 6 is preferably composed of a printed layer, which is made by printing a transparent cover film 4.

[0040] The masking film 4 itself is made of a light-transmitting, glass-like thermoplastic material, for example, by extrusion. While the masking film 4 is flat, it is printed with color and / or structure and / or decoration and / or optical microstructures to create the masking sections 6 or optical structures in the edge sections 6 or main sections 5 of the masking film 4. In another step, the masking film 4 is shaped using a thermoforming mold under applied heat and / or pressure, such that the edge sections 6 extend from the main sections 5 at a predetermined angle α. The masking film is now complete.

[0041] For mounting the lighting equipment, a sealing strip 10 is applied, preferably adhesively applied, to the outer side 11 of the opening edge 9 of the housing 1. See [reference needed]. Figure 3 In the next step, the cover film 4 is placed on the housing 1 while covering the opening of the housing 1, wherein the edge flange 7 of the cover film 4 is in contact with the sealing strip 10 around it. If the sealing strip 10 has an adhesive surface on the outside, the edge flange 7 of the cover film 4 can be adhesively attached to the housing 1. Thus, it is in the assembled position. In the final step of the process, the clamping element 13 is abutted against the outside of the edge flange 7 while surrounding the fixing strip 14. By manipulating the fixing adjustment member 15 in the sense of tensioning the fixing strip 14, a force-locked connection is thus achieved between the edge flange 7 of the cover film 4 and the opening edge 9 of the housing 1.

[0042] List of reference numerals

[0043] 1. Shell

[0044] 2 Bottom

[0045] 3, 3', 3" wall

[0046] 4. Masking film / mask

[0047] 5 main sections

[0048] 6 edge sections / obstructed sections

[0049] 7 Edge flange

[0050] 8 edge edges

[0051] 9 Opening edge

[0052] 10 sealing strips

[0053] 11 outer

[0054] 12 edge splicing pieces

[0055] 13 clamping elements

[0056] 14 fixing straps

[0057] 15 Fixed Adjustment Components

[0058] α angle

[0059] b R b D width

[0060] w D w A Wall thickness

[0061] h R high

[0062] F tension

[0063] l B l R length

Claims

1. A lighting device for a vehicle, the lighting device having a shell-shaped housing (1) in which a number of optical components are arranged for generating one or more light functions having a predetermined light distribution, wherein, The housing (1) has a bottom (2) and a wall (3) protruding from the bottom (2), the wall having an opening edge (9) and an edge ridge (8) of the opening edge (9), the edge ridge defining an opening of the housing (1), and the lighting device having a cover plate (4) fixedly connected to the housing (1) in the region of the edge ridge (8) of the opening edge (9), characterized in that the cover plate is constructed as a printable cover film (4), the cover film being forcefully connected to the opening edge (9) of the housing (1) by a surrounding edge flange (7).

2. The lighting device according to claim 1, characterized in that, The edge flange (7) of the covering film (4) is fixed to the opening edge (9) of the housing (1) by means of the surrounding clamping element (13).

3. The lighting device according to claim 2, characterized in that, The length (l) of the clamping element (13) B ) at least corresponding to the length (l) of the opening edge (9) R ).

4. The lighting device according to claim 2 or 3, characterized in that, The clamping element (13) has a fixing band (14) that is planar against the outside of the edge flange (7) and a fixing adjustment member (15) for tensioning the fixing band (14).

5. The lighting device according to claim 4, characterized in that, The fixing strap (14) is made of metal or textile material.

6. The lighting device according to claim 4 or 5, characterized in that, The opening edge (9) of the housing (1) is configured to be flat and / or outwardly arched, such that the fixing strap (14) is circumferentially and uninterruptedly abutted against the opening edge (9) of the housing (1) in the assembled position.

7. The lighting device according to any one of claims 4 to 6, characterized in that, A sealing strip (10) is arranged between the fixing strip (14) of the clamping element (13) and the outer side (11) of the opening edge (9).

8. The lighting device according to claim 7, characterized in that, The sealing strip (10) is adhesively connected to the housing on the inner side of the outer side (11) facing the housing (1) and / or adhesively connected to the edge flange (7) on the outer side of its edge flange (7) facing the covering film (4).

9. The lighting device according to claim 7 or 8, characterized in that, The sealing strip (10) has a length consistent with the opening edge (9) such that the sealing strip (10) is circumferentially connected to the outer side of the housing (1) and the fixing strip (14) of the covering film (4).

10. The lighting device according to any one of claims 7 to 9, characterized in that, The opening edge (9) of the housing (1) has an outwardly pointing circumferential edge piece (12) arranged on the edge edge (8), and the sealing strip (10) has a wall thickness greater than the height of the edge piece (12), such that the fixing strip (14) only abuts against the sealing strip (10).

11. The lighting device according to any one of claims 1 to 10, characterized in that, The covering film (4) has a wall thickness (w) in the range of 0.5 mm to 1.5 mm, preferably in the range of 0.75 mm to 1.25 mm. A ).

12. The lighting device according to any one of claims 1 to 11, characterized in that, The cover film (4) is configured to be resistant to bending and has a light-transmitting main section (5) and an edge-side blocking section (6), the blocking section (6) having an opaque printed layer.

13. A method for assembling lighting equipment, wherein, The shell-shaped housing (1) and the cover plate (4) that closes the opening of the housing are fixedly connected to each other. The feature is that in a first step, the cover plate (4) is placed in an assembly position while covering the opening of the housing (1), in which the surrounding edge flange (7) of the cover plate (4) is abutted against the opening edge (9) of the housing (1) on the outside, and in a second step, a fixing strap (14) is applied around the edge flange (7) and the fixing strap is tightened so that the edge flange (7) of the cover plate (4) is forcefully locked to the opening edge (9) of the housing (1).

14. The method according to claim 13, characterized in that, Before applying the edge flange (7) of the cover plate (4) to the opening edge (9) of the housing (1), the opening edge (9) of the housing (1) is provided with a surrounding sealing strip (10) on the outside.

15. A method for manufacturing a covering film (4) according to any one of claims 1 to 12, characterized in that, The cover film (4) is made of thermoplastic material, printed with color and / or decoration and / or structure and / or optical microstructure in a flat state, and then shaped by heat and / or pressure, such that the cover film has a main section (5) covering the opening of the housing (1) and a surrounding edge flange (7) extending from the main section (5) at an angle (α).

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