Air deflection element for a ventilation system and vehicle headlamp

Abstract

The invention relates to a wind guide element (100) for a ventilation system of a vehicle headlamp, comprising at least one component body (1) with at least one integrated wind guide channel, wherein the component body (1) is configured as an assembly formed by at least two shell elements (11, 12). According to the invention, the shell elements (11, 12) are made of foamed plastic by means of thermoforming.

Description

Technical Field

[0001] This invention relates to an air guide element for a ventilation system of a vehicle headlight and related vehicle headlights. Background Technology

[0002] Vehicle headlights are equipped with a ventilation system for thermal management during the operation of the included light modules. The ventilation system is particularly effective in preventing overheating and moisture buildup caused by condensation inside the headlight. A key component of the ventilation system is an air guide element, which, in combination with an active fan or by cleverly utilizing convective airflow, ensures proper air circulation within the headlight. For example, air heated by waste heat from the light-emitting devices is directed from the associated light module or matching coolant and concentrated towards the endplate of the headlight for heating, thus suppressing unwanted condensation formation there. The air guide element has a built-in airflow channel through which airflow is conducted. In the prior art, air guide elements are typically assembled from injection-molded shell components. Summary of the Invention

[0003] The objective of this invention is to provide an alternative embodiment of an air guide element for a ventilation system, which is particularly characterized by its light weight and resource-saving manufacturing.

[0004] This task is solved by the air guiding element according to claim 1. Advantageous improvements of the invention are given in the dependent claims.

[0005] Starting with a wind-guiding element having a component body consisting of at least two shell elements, the present invention discloses that the shell elements are made of foamed plastic by means of thermoforming.

[0006] This invention is based on the concept of significantly reducing the weight of air-guiding elements while improving thermal insulation performance by using foamed plastic instead of the solid materials commonly used in the prior art. To this end, the shell element made of foamed plastic has a suitable degree of porosity. To manufacture the shell element, a semi-finished product made of foamed plastic, especially a film or sheet, is formed by thermoforming. This replaces the resource-, energy-, and cost-intensive injection molding process. In thermoforming (also known as hot forming or deep drawing of plastic), a film or sheet-like semi-finished product made of thermoplastic is heated until it becomes plastic and then introduced into a mold using vacuum or compressed air. After cooling and demolding, the component, in this case, the shell element, is punched out of the molded part.

[0007] To form the component body, the shell elements are connected to each other, particularly by means of welding or adhesive bonding. For example, the welding connection can be established immediately after thermoforming by pressing the still-warm shell elements together in a joint area that forms a material-locking bond.

[0008] The shell element has a wall thickness ranging from approximately 0.5 mm to 3 mm. Depending on the specific plastic used and its porosity content, suitable component characteristics regarding mechanical load-bearing capacity, sealing, and thermal insulation can be achieved within this range. Polypropylene is a particularly suitable plastic here. The air-guiding channels extending within the component body have a diameter, for example, ranging from 10 mm to 60 mm, wherein the diameter can be suitably varied along the channels.

[0009] In one embodiment, the air guide element includes at least one receiving device for connection to a vehicle headlight, wherein the receiving device is form-locked, bonded, or welded to the component body. Threaded bosses or snap hooks may be considered as receiving devices, for example. Their geometry and wall thickness are typically not achievable by thermoforming, thus injection-molded components are employed in particular. These injection-molded components can be form-locked onto the corresponding shell element as inserts during thermoforming. Alternatively, if the thickness of the semi-finished product used is suitable, the receiving device can be integrally molded onto the corresponding shell element in one piece with consistent material during thermoforming.

[0010] The present invention also relates to a vehicle headlight, the vehicle headlight comprising at least a light module and a ventilation system for thermal management during operation of the light module, wherein the ventilation system has at least one air guide element according to any of the above embodiments. Attached Figure Description

[0011] Figure 1a and Figure 1b A perspective view of a ventilation element for a vehicle headlight according to the present invention is shown. Detailed Implementation

[0012] An embodiment of the present invention will now be shown and described in detail with reference to the accompanying drawings.

[0013] Figure 1a and Figure 1b A perspective view of an air guide element 100 for a ventilation system for a vehicle headlight according to the present invention is shown. The air guide element includes a component body 1 with a built-in air guide channel, wherein the component body 1 has a complex free shape with a plurality of channel openings 10 that open into the air guide channel as air inlets or outlets.

[0014] According to the present invention, the component body 1 is constructed as an assembly consisting of two shell elements 11 and 12, which are respectively made of foamed plastic by thermoforming. The two shell elements 11 and 12 are welded together along a circumferentially extending joint area 13.

[0015] In addition, the air guide element 100 also includes a receiving device 2, which is configured to connect with a relevant vehicle headlight. The receiving device 2 is constructed as an injection-molded component with high mechanical load-bearing capacity and is form-locked to the component body 1.

[0016] List of reference numerals in the attached diagram:

[0017] 100 air guide element

[0018] 1. Component Body

[0019] 10 Channel Openings

[0020] 11, 12 Shell components

[0021] 13. Joint area

[0022] 2. Receiving device

Claims

1. A guide element (100) for a ventilation system of a vehicle headlight, comprising at least one component body (1) having at least one built-in air guide channel, wherein, The component body (1) is constructed as an assembly formed by at least two shell elements (11, 12), characterized in that the shell elements (11, 12) are made of foamed plastic by thermoforming.

2. The air guiding element (100) according to claim 1, characterized in that, The shell elements (11, 12) are connected to each other by welding or adhesive bonding.

3. The air guiding element (100) according to claim 1 or 2, characterized in that, The shell elements (11, 12) have a wall thickness ranging from 0.5 mm to 3 mm.

4. The air guiding element (100) according to any one of the preceding claims, characterized in that, The air guide channel has a diameter ranging from 10 mm to 60 mm.

5. The air guiding element (100) according to any one of the preceding claims, characterized in that, The foamed plastic contains polypropylene.

6. The air guiding element (100) according to any one of the preceding claims, characterized in that, The air guide element (100) includes at least one receiving device (2) for connection with a vehicle headlight, wherein the receiving device (2) is connected to the component body (1) in a form-locking manner, by means of adhesive connection or by means of welding connection.

7. A vehicle headlight, comprising at least a light module and a ventilation system for thermal management during operation of said light module, characterized in that, The ventilation system has at least one air guiding element (100) according to any one of the preceding claims.

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