A light-emitting module configured to project at least one cutoff beam

Abstract

The invention relates to a light emitting module (1) comprising a light source (2), a collimator (4) and a microlens array device (6), wherein the microlens array device (6) comprises a plurality of light channels (14) comprising an entrance microlens (20) and an exit microlens (22), wherein each entrance light ray (10) falls within an entrance angle range (12) and each refracted light ray falls within a refracted angle range (30), and wherein the entrance microlenses (20) are offset so as to form a step (44), wherein an angle (a) between the step (44) and a reference direction (R) lies between a first limit (36) defining the entrance angle range (12) and a second limit (42) defining the refracted angle range (30).

Description

[0001] This invention relates to the field of light-emitting modules intended for mounting in vehicles, and more particularly to such light-emitting modules designed to conform to the body contours of the vehicle to which they are mounted.

[0002] Vehicles, especially motor vehicles, are typically equipped with headlights, which enable various lighting functions, specifically illuminating the road or signaling the presence of a vehicle to other users. Illumination corresponds to high beam functionality or low beam functionality (i.e., stop beam functionality). Signaling corresponds to, for example, but not limited to, parking light functionality or turn signal functionality.

[0003] For stylistic and aesthetic reasons, for example, the light-emitting module may be designed to fit certain surfaces of the vehicle it is intended to mount on, such as the outer lens of a headlight or the front fascia of the vehicle. These vehicle surfaces are not always flat, so it is necessary to adjust the light-emitting module to fit these non-flat surfaces. Alternatively, there may be a substantially flat outer lens or front fascia, and it may be desirable to produce a light-emitting module offset from it to create a sense of depth. In both cases, the light-emitting module is configured such that the emitting surface of the light-emitting module (that is, the surface of the light-emitting module intended to face the outer lens or front fascia) has a controlled and adaptable shape.

[0004] In some applications, one of the aforementioned optical functions is achieved via light emitted from a light source through a microlens array (MLA) device. Specifically, the microlens array device includes an optical channel formed by an incident microlens and an exiting microlens, which are focused such that light entering through the incident microlens propagates within the microlens array device through a dedicated optical channel, and exits through the exiting microlens associated with that optical channel.

[0005] Specifically, microlens array devices are known to have an opaque mask within them, and an incoming microlens array and an outgoing microlens array attached to both sides thereof, each array focusing on the mask and on an aperture formed in the mask. Maskless microlens array devices are also known, wherein the outgoing microlens array is directly adjacent to the incoming microlens array, and the incoming microlens converges on the corresponding outgoing microlens, and the outgoing microlens focuses on the corresponding incoming microlens.

[0006] It is advantageous to manufacture the microlens array device by plastic injection molding in order to impart a specific curvature to the device, particularly by offsetting the incident surfaces of the incident microlenses and / or the exit surfaces of the exit microlenses from each other. In this respect, it is particularly advantageous not to place a mask between them, as masks are made of opaque glass plates, and this would hinder flexibility in arrangement.

[0007] In the context of plastic injection molding of microlens array devices, it is necessary to provide a draft angle from one optical channel to an adjacent optical channel in order to allow the part to be demolded after injection molding.

[0008] However, the presence of a draft angle necessary for mechanical reasons should not have optical consequences. Therefore, it is important to prevent the propagation of stray rays within the microlens array device, as stray rays can otherwise hinder or interfere with the implementation of the selected optical function. In maskless microlens array devices, the management of stray rays is particularly important, since the mask typically plays a role in preventing the occurrence of these stray rays.

[0009] This invention pertains to this context, and therefore its main subject is a light-emitting module for a motor vehicle, configured to project at least one light beam along the optical axis of the light-emitting module. The light-emitting module includes at least one light source, a collimator, and a microlens array. The light source is configured to emit light toward the microlens array through the collimator. The microlens array includes: a main incident surface intended to receive incident light from the light source that has passed through the collimator; a main exiting surface disposed opposite to the main incident surface; and a plurality of optical channels, each including an incident microlens and an exiting microlens, each optical channel formed by components contributing to the formation of the main incident surface. The light-emitting module is configured such that each incident ray received by the main incident surface is within an incident angle range, and each ray refracted by the main incident surface to propagate in the direction of the main exit surface within the optical channel is within a refraction angle range. At least some of these incident microlenses are offset from other incident microlenses to form a step between two adjacent incident microlenses. At least one step is configured such that the angle between the step and the reference direction of the light-emitting module falls between a first limit defining the incident angle range relative to the reference direction and a second limit defining the refraction angle range relative to the reference direction.

[0010] The light-emitting module according to the invention is intended to be fitted into a motor vehicle to perform at least one light function, wherein a light beam generated by the light-emitting module for performing the light function is projected along the optical axis of the light-emitting module.

[0011] The light-emitting module includes one or more light sources for emitting light in the direction of a collimator. The collimator functions to transform the light emitted by the light sources and guide these rays as parallel incident beams toward the array device. More precisely, the incident rays arriving at the array device are parallel within a divergence angle range related to the dimensions and parameters of the various elements forming the light-emitting module. Therefore, each incident ray falls within an incident angle range defined by two angular value limits relative to a reference direction.

[0012] Microlens arrays (MLAs) are made of injectable materials (e.g., plastic materials). A microlens array device includes multiple optical channels for propagating incident light arriving at the array device. These optical channels extend between an incident surface and an exit surface facing a collimator, which are also inscribed within the main incident surface and the main exit surface of the microlens array device, respectively. Each optical channel consists of an incident microlens and an exit microlens, wherein the incident microlens includes the incident surface of the optical channel, and the exit microlens includes the exit surface of the optical channel.

[0013] In this configuration, the incident microlens and the exiting microlens form a continuation of each other; in other words, they are adjacent to each other within the optical channel. More specifically, no mask is placed between the incident and exiting microlenses. In this context, each incident microlens can be configured to converge light onto its corresponding exiting microlens, i.e., configured such that the image focus is substantially located on the exiting microlens, and each exiting microlens can then be configured to image the corresponding incident microlens, i.e., configured such that the object focus is substantially located on the incident microlens. Alternatively, each incident microlens can be configured to have an image focus that coincides with or substantially coincides with the object focus of its associated exiting microlens, taking into account manufacturing tolerances. Alternatively, each type of microlens described above can be found within the same microlens array device.

[0014] The light rays emitted from the collimator are received by the main incident surface, and more specifically by the incident surfaces of each optical channel. These light rays pass through the incident surfaces to propagate in the direction of the exit surface within the microlens array device. The light rays that propagate through the thickness of the array device are refracted by the incident microlenses.

[0015] Within a microlens array, particularly due to the aforementioned range of incident angles, each refracted ray falls within a range of refraction angles defined by two angular values ​​relative to a reference direction.

[0016] For a given point on the incident surface of the array device, the range of incident angles indicates that multiple incident rays can reach that incident surface at variable incident angles, and the range of refraction angles indicates that multiple refracted rays can propagate from that incident surface within the optical path at variable refraction angles. The existence of these angular ranges is primarily due to the fact that the light source is not a point source, but a surface source with a large area. More specifically, the divergence angle resulting in this angular range is defined by the lateral dimension of the light source relative to the focal length of the collimator. This divergence angle, or range of incident angles, is the angle corresponding to the observation of the light source at the collimator focal length. Therefore, for the same focal length, the larger the light source, the larger the divergence angle. Alternatively, for a light source of the same size, the shorter the focal length, the larger the divergence angle. Potential optical aberrations may be a secondary reason contributing to the increase in these angular ranges.

[0017] It is worth noting that, due to the refraction of light within the incident angle range on the incident surface, the refraction angle range can be an angle range of a different size than the incident angle range. The refraction angle depends on the curvature of the incident surface and the refractive index of the material forming the microlens array device.

[0018] It should also be noted that for incident rays, these directions are parallel within the divergence angle. The divergence angle is the same regardless of the incident area on the incident plane. For refracted rays, the divergence angle is also the same regardless of the area on the incident plane, but the direction may change.

[0019] Within the light-emitting module, the reference direction corresponds to the direction parallel to the optical axis and passing through the incident point of a given ray into a given incident microlens. Therefore, it should be understood that there exists a reference direction associated with each ray.

[0020] The main incident surface of the microlens array device is non-planar; specifically, not all incident microlenses extend in the same plane, and at least some of these incident microlenses are offset relative to other incident microlenses. In one embodiment, each incident microlens may be configured to be offset relative to other incident microlenses, and alternatively, some adjacent microlenses may not be offset, particularly when multiple (e.g., a pair) incident microlenses are associated with the same optical channel.

[0021] In this way, there is an offset or step between two adjacent incident microlenses, particularly between two adjacent incident surfaces. Referring to the optical axis of the light-emitting module or the reference direction mentioned above, this offset should be considered axial. More specifically, this offset from one incident surface to another will be considered in the main extension direction of the optical channel.

[0022] In the context of producing light-emitting modules via injection molding, these steps must be at an angle relative to the main extension direction of the light channel, a value sufficient to allow the part to be demolded. Therefore, the orientation of these steps must meet the mechanical requirement that an angle (called the draft angle) is required.

[0023] To limit stray light within the microlens array and, preferably, to completely prevent any stray light, the step between two adjacent incident microlenses has a predetermined angle depending on the directions of the incident and refracted rays. Therefore, the orientation of the step must meet optical requirements.

[0024] This angle is configured to prevent light from passing through the step, whether by incident light passing directly without passing through the incident surface or by refracted light passing indirectly after being deflected by the incident surface. Therefore, the light-emitting module is configured so that light enters through the incident surface of the incident microlens instead of through the step, and propagates within the light channel after passing through the incident surface without being reflected at the step.

[0025] The feature of this invention (according to the invention, the angle between the step and the reference direction of the light-emitting module lies between a first limit defining the range of incident angles relative to the reference direction and a second limit defining the range of refraction angles relative to the reference direction) is particularly applicable to refracted light generated due to incident light reaching the incident surface immediately adjacent to the step. "Immediately adjacent" means that the distance along the corresponding direction is less than 10% of the size of the incident surface in question.

[0026] Throughout the preceding and present document, microlenses are referred to; however, it should be noted that microlenses may be referred to in a similar manner without departing from the scope of the invention. According to an advantageous embodiment of the invention, the projection lens (whether referred to as a microlens or microlens) has a diameter, height, and / or width of 10 mm or less when viewed from the front. This allows for limiting the thickness of the lens, and thus the weight of the part. According to an advantageous embodiment of the invention, these projection lenses have a diameter, height, and / or width of 0.3 mm or greater when viewed from the front. This allows for the manufacture of the optical device by means of a simple injection molding process. Furthermore, according to an advantageous embodiment of the invention, the projection lens has a size between 1 mm and 5 mm in diameter, height, and / or width when viewed from the front. This allows the projection lens to be made small enough to be undetectable at normal viewing distances.

[0027] According to one feature of the invention, at least 50% of the steps of the main incident surface have an angle between the first boundary and the second boundary; preferably, at least 80% of the steps of the main incident surface have an angle between the first boundary and the second boundary.

[0028] Specifically, the light-emitting module can be configured to implement a cutoff illumination function. This illumination function, for example, has an upper horizontal cutoff line in the case of low-beam headlights, or a lateral cutoff line in the case of adaptive anti-glare lighting systems (also known as "matrix beams"). In this context, where the light-emitting module includes an array and allows for the implementation of the cutoff illumination function, controlling the draft angle value between two adjacent microlenses defining adjacent light channels allows this function to be implemented in the case of a maskless array without the function being negatively affected by excessive stray light, whereas in the case of an array with a mask placed between the incident and exit microlenses, stray light is blocked by the presence of the mask.

[0029] According to an optional feature of the invention, the first limit corresponds to the incident ray closest to the reference direction within the incident angle range, and the second limit corresponds to the refracted ray closest to the reference direction within the refraction angle range.

[0030] For a given range of incident angles, the first limit corresponds to the incident ray that readily forms the smallest angle with the reference direction. For a given range of refraction angles, the second limit is the refracted ray that readily forms the smallest angle with the reference direction. Depending on the ascent or descent angle of the incident rays, i.e., whether these incident rays form a negative or positive angle with the reference direction (measured from the reference direction to one of the incident rays), the first limit can form a negative or positive angle with the reference direction, and the second limit can form an angle with the reference direction in the opposite direction.

[0031] According to an optional feature of the invention, the incident surfaces of the optical channels are offset relative to each other in a direction parallel to the reference direction.

[0032] In other words, the incident surfaces of the optical channels are offset relative to each other in the main extension direction of the optical channels. For example, the incident surfaces are offset relative to each other in a direction parallel to the optical axis. In the main incident surface of a microlens array device, it is the presence of steps that causes the offset between the incident surfaces of the various optical channels.

[0033] According to an optional feature of the invention, the incident surface of the optical channel is shifted according to a monotonic function.

[0034] It should be understood that the incident surface receiving incident light from the light source follows an increasing or decreasing function. According to embodiments, particularly in the presence of multiple light sources, the incident surface of the optical channel shifts according to a piecewise monotonic function.

[0035] According to an optional feature of the invention, the incident surfaces of the optical channels are arranged symmetrically around axes parallel to the reference direction.

[0036] Similarly, the exit surfaces of the optical channel are arranged symmetrically around axes parallel to the reference direction. Due to the presence of the steps and the angle formed by the steps and the reference direction, the parallel axis centered on the incident surface does not coincide with the parallel axis centered on the exit surface.

[0037] According to an optional feature of the invention, at least some of the steps arranged between the incident surfaces of the microlens array device, which are intended to receive incident light from the same light source, are parallel to the other steps. Therefore, if the light-emitting module is configured to exclusively fit a vertical profile, all steps are parallel to each other in a substantially horizontal orientation. Similarly, if the light-emitting module is configured to exclusively fit a horizontal profile, all steps are parallel to each other in a substantially vertical orientation. If the steps are formed within the microlens array device such that they can fit both horizontal and vertical profiles, the parallelism of the steps relative to each other will be taken into account in a given cross-sectional plane including the reference direction.

[0038] According to an optional feature of the invention, the size of the step increases with the distance along the optical axis.

[0039] Specifically, the size of a given step extending between the first incident microlens and the adjacent second incident microlens corresponds to the size measured substantially in the main extension direction of the optical channel between the incident surfaces of the first and second incident microlenses.

[0040] According to an optional feature of the invention, at least some of these optical channels have a different thickness than the other optical channels, the thickness of which is measured between the incident and exit surfaces of the channel.

[0041] For example, this thickness is measured between the midpoint of the incident surface and the midpoint of the exit surface, and, for example, when an axis parallel to the reference direction passes through the two end faces of the channel, this thickness is measured parallel to that reference direction. The different thicknesses of the optical channels relative to each other help to adapt the main exit surface of the microlens array device to the shape of the vehicle.

[0042] According to an optional feature of the invention, the light-emitting module includes an additional light source, and the incident light rays from the light source and the incident light rays from the additional light source have different incident angles at the collimator exit.

[0043] An additional light source can allow the implementation of the same light function as the original light source, particularly a cutoff line light function. In this case, the light-emitting module is a single-function light-emitting module. Alternatively, an additional light source can allow the implementation of a different light function than the cutoff line light function. In this case, the light-emitting module is a dual-function light-emitting module. This light function is, for example, a signal light function; in any case, this light function is a cutoff line-free light function.

[0044] According to an optional feature of the invention, the light-emitting module includes a partition disposed between incident light from a light source and incident light from an additional light source. The partition may be, in particular, opaque.

[0045] According to an optional feature of the invention, at least some of the incident surfaces of the optical channel receiving incident light from an additional light source are offset relative to other incident surfaces in a direction parallel to a reference direction, and these incident surfaces are offset according to a monotonic function.

[0046] According to an optional feature of the invention, the monotonic function followed by the incident light rays received by the incident surface from the light source and the monotonic function followed by the incident light rays received by the incident surface from the additional light source are different functions.

[0047] The monotonic function of the principal incident surface is thus a piecewise monotonic function. For example, the monotonic function followed by incident rays from the light source and the monotonic function followed by incident rays from the secondary light source are in opposite directions. These monotonic functions can, for instance, be symmetric.

[0048] According to an optional feature of the invention, the divergence angle of the collimated beam (i.e., the beam from the collimator) is between 1.4° and 3°. More specifically, for characteristic light-emitting diodes with dimensions between 0.2 mm and 2 mm and collimators with focal lengths between 10 mm and 100 mm, the divergence angle of the collimated beam can be between 0.1° and 12°, where the value is 0.1° for a 0.2 mm light source and a 100 mm focal length, and 12° for a 2 mm light source and a 10 mm focal length. In the common case where the side length of the light source is between 0.5 mm and 1 mm and the focal length of the collimator is approximately 20 mm, the divergence angle is between 1.4° and 3°. The size of the light source and the focal length of the collimator are the parameters that most significantly affect the divergence angle of the collimated beam.

[0049] According to an optional feature of the invention, the convergence of the incident microlens is between -6° and 6°. In other words, the light rays refracted inside the lens are refracted relative to the optical axis at angles within this range. More specifically, considering the critical case where the refracted rays converge at a point on the exit surface and there is almost no light power at the incident surface, the angles of these refracted rays are in the range of + / - arctan((lens_height / 2) / lens_thickness). For a lens with a side length of 1 mm and a thickness of 5 mm, the refracted rays can be between + / - 5.7°, i.e., approximately + / - 6°, taking into account potential aberrations. More generally, for a given image focal length of the incident lens, the angles of the refracted rays are in the range of + / - arctan((lens_height / 2) / image focal length of the incident lens).

[0050] The convergence of the incident microlens contributes to determining the range of refraction angles of the refracted rays.

[0051] Other features, details, and advantages of the invention will become clearer, on the one hand, by reading the following description, and on the other hand, by referring to the exemplary embodiments given in a non-limiting manner with reference to the accompanying drawings, in which: [ Figure 1 The first embodiment of the light-emitting module according to the present invention is illustrated schematically. The light-emitting module includes a light source, a collimator, and a microlens array device, wherein the light reaching the microlens array device is downward-sloping light. [ Figure 2 The diagram schematically illustrates the light path through the main incident surface of the microlens array device, showing in particular the various incident light beams and corresponding refracted light beams reaching the incident surface. The diagram also shows that there are steps between two adjacent incident surfaces of the array device, and the inclination of these steps depends on the inclination of the incident and refracted light beams. [ Figure 3 ]Symbolic illustration Figure 1 A variant embodiment of the light-emitting module and its microlens array device; [ Figure 4 The illustration schematically shows a second embodiment of a light-emitting module according to the present invention, which includes multiple light sources, a collimator, and a microlens array device.

[0052] [ Figure 5 The figure schematically illustrates the light-emitting module of a first embodiment of the microlens array device in which upward-tilted light rays reach, highlighting a step with a tilt that is correctly adapted to the tilt of the incident light rays. [ Figure 6 The figure schematically illustrates a light-emitting module with an upward-tilted light source, highlighting a step with a tilt that does not match the tilt of the incident light and results in stray light generation. [ Figure 7 The figure schematically illustrates a light-emitting module with an upward-tilted ray, highlighting a step with a tilt that is correctly adapted to the tilt of the refracted ray. [ Figure 8 The diagram schematically illustrates a light-emitting module with an upward-tilted ray, highlighting a step with a tilt that does not match the tilt of the refracted ray and results in total internal reflection.

[0053] The features, variations, and various embodiments of the present invention can be combined with each other in various combinations, provided that they are not mutually incompatible or mutually exclusive. In particular, it is conceivable that variations of the invention may include only the selection of features described below in isolation from the other features described, provided that such selection of features is sufficient to provide technical advantages and / or distinguish the invention from the prior art.

[0054] In these figures, elements shared by multiple figures retain the same reference numerals.

[0055] therefore, Figures 1 to 4 The illustration schematically demonstrates the invention, according to... Figures 1 to 3 and Figures 5 to 8 The first embodiment and according to Figure 4 The second embodiment of the light-emitting module 1.

[0056] The light-emitting module 1 is configured to be disposed within a motor vehicle, for example, behind the outer lens of a headlight in the front of the vehicle. More specifically, the light-emitting module 1 is intended to be fitted to a region of the motor vehicle having a certain contour in order to perform at least one of its light functions, and the light-emitting module 1 is configured to have an emitting surface for light rays participating in performing the light function, the emitting surface being substantially adapted to the contour of that region of the vehicle.

[0057] In the first embodiment, the light-emitting module 1 is more specifically designed to implement an illumination function with a cutoff line, for example, the cutoff line may correspond to the low beam illumination function of a headlight, wherein the cutoff line in the beam projected by the light-emitting module is an upper horizontal cutoff line. Alternatively, the light function corresponds to an illumination function performed by an adaptive anti-glare lighting system that enables the acquisition of a matrix illumination beam including vertical stripes and allows the selective shut-off of the matrix illumination beam to prevent road users from being dazzled without reducing the brightness of the remaining portion of the beam, and the cutoff line is a lateral cutoff line.

[0058] Furthermore, the light-emitting module as described is particularly advantageous when applied to lighting functions with a cutoff line, provided that it can effectively manage the appearance of stray light that may negatively affect such function; however, it should be noted that such a light-emitting module that manages the appearance of stray light can also be used for signal functions or lighting functions without a cutoff line.

[0059] In the second embodiment, the light-emitting module 1 can be a single-function light-emitting module or a dual-function light-emitting module. In the case of a single-function light-emitting module, the light function can specifically correspond to the aforementioned light function with a cutoff line. In the case of a dual-function light-emitting module, in addition to the light function with a cutoff line, the light-emitting module can also specifically provide a light function without a cutoff line. In particular, this light function without a cutoff line can consist of a signal function.

[0060] The various components of the light-emitting module 1 will now be described in detail. The light-emitting module 1 includes at least one light source 2, a collimator 4, and a microlens array device 6. In the first embodiment, and particularly as in... Figure 1 As can be seen, the light-emitting module 1 includes only one light source 2. In the second embodiment and as shown... Figure 4 As shown, the light-emitting module has the light source 2 and an additional light source 8. As will be understood from the foregoing, in the case of the single-function light-emitting module 1, the additional light source 8 is allocated to achieve the light function of the cutoff line in a complementary manner to the function of the first light source 2, and in the case of the dual-function light-emitting module 1, the additional light source is allocated to achieve the light function of the cutoff line-free light.

[0061] Unless otherwise stated, everything described below with respect to the first embodiment (that is, only with respect to light source 2) is intended to be adapted to the second embodiment having light source 2 and additional light source 8 with the necessary modifications.

[0062] The light source 2, collimator 4 and microlens array device 6 are arranged relative to each other, wherein the collimator is placed between the light source 2 and the microlens array device 6, such that the light emitted from the microlens array device 6 forms a light beam 100, which is projected onto the road scene in front of the motor vehicle along the optical axis O of the light-emitting module 1.

[0063] The light beam is generated by optically processing the light emitted by the light source 2. More specifically, the light source 2 emits multiple light rays in the direction of the microlens array device 6 via a collimator 4. Within the collimator 4, the light rays from the light source 2 are collimated, that is, these light rays are parallel to each other. Therefore, at the exit point of the collimator 4, in other words, between the collimator 4 and the microlens array device 6, the light rays are in the form of a collimated beam of light rays that are parallel to each other and point towards the incident surface of the microlens array device. In the remainder of the specification, this collimated beam of light rays will be considered in terms of its effect on the incident surface, and thus the light ray forming this collimated beam of light rays will be referred to as the incident ray 10.

[0064] Furthermore, it should be noted that although collimators will be described with reference to lenses in the remainder of the specification, without departing from the scope of the invention, a collimator may be formed of multiple lenses, each of which is designed to illuminate a specific area of ​​the array device. Advantageously, beams from different collimators do not overlap, or even partially overlap.

[0065] Specifically, the light source 2 is arranged in the focal plane of the lens forming the collimator 4, such that the light emitted from the collimator forms the collimated light beam, and the light source and / or the collimator is offset relative to the optical axis, such that the collimated light beam has an overall tilt angle relative to the optical axis as it propagates between the collimator 4 and the microlens array device 6.

[0066] It should be noted that within the light-emitting module 2, the incident light rays 10 are not perfectly parallel in their arrangement to form collimated beams. Therefore, if the divergence angles related to the dimensions and parameters of the various components of the light-emitting module 2 are ignored, the incident light rays 10 are considered parallel. Thus, each incident light ray 10 should be considered to be able to extend within an incident angle range 12, the magnitude of which reflects the divergence properties of the entire optical system. Figure 2 This incident angle range 12 is shown more specifically in the diagram. For a given point on the incident surface 24, due to dimensional tolerances of the optical system and any optical aberrations, the incident beam 10 that theoretically arrives at that point at a given incident angle may arrive at different incident angles within the incident angle range. The incident angle range 12 and its effect on imparting shape to the microlens array device, and in particular to the main incident surface 16 of the microlens array device 6, will be described in detail below.

[0067] The size and parameters of the light-emitting module 2, which may affect the formation of the divergence angle and thus the incident angle range 12, are mainly the size of the light source 2 and the focal length of the collimator 4.

[0068] Additionally, in the presence of multiple light sources, i.e., when there are... Figure 4 In the second embodiment of the light source 2 and the auxiliary light source 8 shown, both light source 2 and the auxiliary light source 8 emit light through collimator 4, and the different positions of these light sources on the focal plane mean that, independent of the divergence effect caused by collimator 4, the incident light ray 10 from light source 2 and the incident light ray 10 from auxiliary light source 8 are not parallel. In other words, the incident light ray 10 emitted by light source 2 and the incident light ray 10 emitted by auxiliary light source 8 form different incident angles relative to the reference direction R (which is substantially parallel to the optical axis O). Therefore, the incident light ray 10 from light source 2 and the incident light ray 10 from auxiliary light source 8 extend in intersecting directions. The incident light ray 10 emitted by light source 2 propagates towards the microlens array device 6 at a positive angle relative to the optical axis O, and the incident light ray 10 emitted by auxiliary light source 8 propagates at a negative angle relative to the optical axis. The incident light rays are guided onto the array device, and the incident surface is configured to correct the light rays in a suitable manner so that the desired illumination beam 100 can be formed primarily along the optical axis O at the exit surface, such that the incident surface, intended to correct light rays with positive angles, cannot correct light rays with negative incident angles. In this context, as shown in the second embodiment, the light-emitting module 1 may be provided with a partition 13. This partition 13 is arranged between the collimator 4 and the microlens array device 6. The partition 13 (advantageously opaque) separates the incident light rays 10 from each of the light sources 2, 8, and thereby prevents any interaction between the incident light rays 10 and the portion of the incident light rays not intended for use with the microlens array device.

[0069] The incident light rays 10 emanating from the collimator 4, whether from the light source 2 or the auxiliary light source 8, are intended to pass through the microlens array device 6 and then exit from the light-emitting module 1 as an illumination beam, particularly an illumination beam with a cutoff line. The microlens array device 6 consists of a plurality of optical channels 14 arranged adjacent to each other and vertically above each other, extending between the main incident surface 16 and the main exit surface 18 of the microlens array device 6. The main incident surface 16 of the microlens array device 6 is arranged to face the collimator 4, while the main exit surface 18 faces the opposite direction.

[0070] More specifically, each optical channel 14 is formed by an incident microlens 20 and an exit microlens 22, which are adjacent to each other in this case. In other words, the microlens array device 6 does not have a mask that would otherwise be placed between the incident microlens 20 and the exit microlens 22. Therefore, the microlens array device 6 is formed by an array of incident microlenses and an array of exit microlenses that are adjacent to each other.

[0071] In this configuration, each optical channel 14 extends in a main extension direction defined by an incident surface 24 and an exit surface 26. The incident surface belongs to its incident microlens 20 and participates in forming the main incident surface 16 of the microlens array device 6, and the exit surface belongs to its exit microlens 22 and participates in forming the main exit surface 18 of the microlens array device 6.

[0072] The thickness E of the optical channels 14 corresponds to the dimension of these optical channels measured between their incident surface 24 and their exit surface 26. This thickness E varies between the individual optical channels 14. Decreasing or increasing the thickness E of the optical channels 14 leads to alternative embodiments of the microlens array device 6, for example, Figure 1 The first variant embodiment shown has a microlens array device 6 compared to... Figure 3 The microlens array device 6 (which corresponds to the second variant embodiment) is thinner.

[0073] As can be seen in the figure, the incident surfaces 24 of all optical channels 14 are centered on an axis parallel to the reference direction R and the optical axis O. The term "centered" here should be understood as meaning that the incident surfaces are arranged substantially symmetrically around an axis parallel to the reference direction. Similarly, the exit surfaces 26 of all optical channels 14 are centered on an axis parallel to the reference direction R. Furthermore, the principal extension direction of each optical channel in the optical channels 14 formed between the incident surfaces 24 and the exit surfaces 26 is substantially parallel to the reference direction R and the optical axis O.

[0074] The incident light 10 enters the microlens array device 6 through refraction at the main incident surface 16, and more specifically through the incident surfaces 24 of each optical channel 14. The light propagates within each optical channel of the microlens array device 6, and then exits the microlens array device via its main exit surface 18, or more precisely via the exit surfaces 26 of its various optical channels 14.

[0075] The incident microlens 20 is configured such that light rays 28 refracted by the incident surface 24 of the incident microlens 20 converge toward the exit surface 26 of the exit microlens 22 associated with the incident microlens. More specifically, in applications where a light-emitting module is placed masklessly between the incident and exit microlenses to generate a cutoff line beam, each incident microlens 20 is configured such that refracted light rays 28 converge toward the associated exit microlens 22 within the optical channel 14, and each exit microlens 22 images the incident surface 24 of the corresponding incident microlens 20.

[0076] It should be understood that these refracted rays 28 are not strictly parallel to each other, especially since the incident rays 10 from which these refracted rays originate may have incident angles that vary depending on aberrations and optical tolerances in the system. For a given point on the incident surface of the microlens array device, a theoretically incident ray illuminating the incident surface at the theoretical incident angle is refracted into a theoretically refracted ray with a theoretical angle of refraction. However, an actual incident ray illuminating that given point at an incident angle different from the theoretical incident angle may produce a refracted ray with a different angle of refraction than the theoretical angle of refraction. For each refracted ray 28 from a given point on the incident surface of the array device, this results in a range of refraction angles 30, which includes multiple possible angles of refraction that the refracted ray from the given point may present around the refracted ray 28. The value of this range of refraction angles 30 (especially...) Figure 2 (As can be seen in the image) It may also be affected by the convergence of the incident microlens 20. For example, the convergence of the incident microlens 20 is between -6° and 6°.

[0077] Now refer to Figure 2 The incident angle range 12 and the refraction angle range 30 are described in detail. As mentioned above, the incident angle range 12 surrounds each incident ray 10, and the refraction angle range 30 surrounds each refracted ray 28. The incident angle range 12 demonstrates the fact that multiple rays exiting the collimator can reach the same point on the incident surface 24 of a given incident microlens 20 at variable incident angles, which is particularly due to optical aberrations and the specific dimensions of the light-emitting module. Similarly, the refraction angle range 30 demonstrates the fact that multiple rays can propagate within the optical channel from the same point on the incident surface 24 of a given incident microlens 20 at varying refraction angles.

[0078] The incident angle range 12 is defined by two boundaries, which correspond to the two extreme incident rays 32 and 34 with the maximum inclination relative to the theoretical incident ray 10, particularly... Figure 2 The two extreme incident rays 32 and 34 are depicted with solid lines. They are depicted with dashed and dotted lines, respectively, and are located on either side of a given incident ray 10. These two extreme incident rays 32 and 34 are collimated rays that readily illuminate the incident surface at the same point as the theoretical incident ray 10, at the maximum and minimum incident angles measured relative to the reference direction R, respectively. More precisely, one of these extreme incident rays (here, the first extreme incident ray 32) forms a smaller angle with the reference direction R than the other, causing it to reach the incident surface in a flatter manner (that is, its tilt angle, relative to the theoretical incident ray, tends to bring the first ray closer to the optical axis). This first extreme incident ray 32, which forms the smallest absolute angle with the reference direction R, corresponds to a first limit 36 ​​of the incident angle range 12, which then defines the shape of the microlens array device 6, while the other extreme incident ray defines another limit of the incident angle range 12. The first limit 36 ​​is defined as forming a first angle α1 with the reference direction R.

[0079] In the same manner, the range of refraction angles 30° is defined by two boundaries corresponding to the two most divergent refracted rays 38 and 40 located on either side of the theoretical refracted ray 28, which, in particular... Figure 2 The two most divergent refracted rays 38 and 40 (depicted by dashed and dotted lines, respectively) are generated by the refraction of the extreme incident rays 32 and 34 mentioned above. These two most divergent refracted rays 38 and 40 are refracted rays that readily propagate from the same point on the incident surface as the theoretical refracted ray 28, and have the maximum and minimum angles of refraction measured relative to the reference direction R, respectively. More specifically, one of these divergent refracted rays (here, the first divergent refracted ray 38) has the maximum angle with the reference direction R and forms a boundary of the refraction angle range 30, and the other of these divergent refracted rays (here, the second divergent refracted ray 40) has the minimum angle with the reference direction R and corresponds to another boundary of the refraction angle range, here called the second boundary 42, which will be used below to define the shape of the microlens array device 6. The second boundary 42 is defined as forming a second angle α2 with the reference direction R.

[0080] As can be seen in the figure, the main incident surface 16 of the microlens array device 6 is non-planar; the incident microlenses 20 are offset relative to each other, and therefore the incident surfaces 24 of the optical channels 14 are also offset relative to each other. More specifically, the incident surfaces 24 of the optical channels 14 are offset relative to each other in a direction parallel to the reference direction R and the optical axis O.

[0081] like Figure 1 and Figure 2 As shown, the incident surface 24 of the optical channel 14 shifts according to a monotonic function, causing the incident surface to move closer to or further away from the collimator 4. Figure 4 In a specific case of the second embodiment shown, the incident surface 24 of the optical channel 14 is shifted according to a piecewise monotonic function; therefore, the incident surface 24 receiving light from the light source 2 is shifted according to a first monotonic function, and the incident surface 24 receiving light from the auxiliary light source 8 is shifted according to a second monotonic function. Here, for example, the first monotonic function increases from the optical axis O, that is, it tends to move the incident microlens 20 closer to the collimator 4 as the distance from the optical axis O increases, and the second monotonic function corresponding to the portion of the array device extending on the other side of the plane passing through the optical axis O also increases from the optical axis O, because it also tends to move the incident microlens 20 closer to the collimator 4 as the distance from the optical axis O increases. Therefore, the main incident surface 16 is substantially symmetrical on both sides of the plane passing through the optical axis O. The exit surface 26 of the optical channel 14 follows the same monotonic function or piecewise monotonic function as the corresponding incident surface 24, except that... Figure 3 Apart from the variant embodiment shown, in this variant embodiment, the exit surface 26 does not follow a monotonic function due to the different thickness of the optical channel 14.

[0082] The offset between the incident microlenses 20 gives the main incident surface 16 a stepped profile, wherein a step 44 is formed between two directly adjacent microlenses 20. More specifically, in this stepped profile, the incident surface 24 forms a facade extending primarily in a plane perpendicular to the optical axis, and the steps 44 connect the incident surfaces in pairs.

[0083] Therefore, each step 44 corresponds to a portion of the incident microlens, which forms a connection between the incident surface 24 of the incident microlens 20 and the incident surface 24 of the adjacent incident microlens 20.

[0084] It should be noted that the incident microlens array is obtained by injection molding a transparent plastic or thermoplastic material (such as polycarbonate (PC)) into a suitable mold. Therefore, step 44 must have a draft angle α relative to the main extension direction of the light channel (i.e., relative to the reference direction R), a value sufficient to allow demolding from its mold during a demolding operation. For example, the minimum draft angle α can be approximately 1°.

[0085] In this way, the inclination of the steps resolves the mechanical manufacturing constraints of the parts. As will now be described, according to the invention, such inclination is also provided to satisfy optical constraints in order to advantageously limit stray light from appearing within the microlens array device due to the presence of these steps.

[0086] For example, especially in Figure 2 As can be seen, step 44 is essentially parallel to the incident ray 10. In the presence of multiple light sources ( Figure 4 The same applies to the second embodiment. The step 44 of the incident surface 24 that receives incident light rays 10 from the light source 2 is substantially parallel to these incident light rays 10, and the step 44 of the incident surface 24 that receives incident light rays 10 from the additional light source 8 is substantially parallel to the incident light rays 10.

[0087] Generally, the steps 44 formed between the incident surfaces intended to receive incident rays of the same collimated beam are substantially parallel to each other. In the second embodiment, the steps 44 of the incident surface 24 receiving the incident rays 10 from the light source 2 are parallel to each other, and the steps 44 of the incident surface 24 receiving the incident rays 10 from the auxiliary light source 8 are also parallel to each other. However, due to the symmetry of the monotonic function followed by the incident surface 24 associated with each light source 2, 8, the steps 44 of the incident surface 24 receiving the incident rays 10 emitted by the light source 2 and the steps 44 of the incident surface 24 receiving the incident rays 10 emitted by the auxiliary light source 8 are not parallel to each other.

[0088] Furthermore, in the illustrated embodiment, it is noteworthy that the size of step 44 increases with increasing distance from the optical axis O, particularly to accommodate the characteristics of thickness differences, and more specifically to accommodate the increase in thickness with increasing distance from the optical axis O. This size of step 44 is measured, for example, between the incident surface 24 of a given incident microlens 20 and the incident surface 24 of the incident microlens 20 directly adjacent to it.

[0089] As mentioned, the presence of step 44 within the light-emitting module 1 may cause interference due to stray light generated by incident light entering the microlens array device 6 via step 44 instead of via the incident surface, or incident light entering via the incident surface at an angle that means these incident rays encounter the step within the microlens array device and undergo total internal reflection upon encountering step 44. To avoid such interference, according to the invention, the tilt angle α formed between a given step 44 and the reference direction R should be taken into account the tilt of light rays propagating upstream and downstream of one of the incident surfaces adjacent to the step.

[0090] More precisely, the angle α formed between the given step 44 and the reference direction R lies between a first limit 36 ​​and a second limit 42, the first limit being defined by the tilt angle of the extreme incident ray at a given contact point on the incident surface, and the second limit being defined by the tilt angle of the extreme refracted ray from the given contact point on the incident surface. It will be understood from the foregoing that the value of the angle α formed between the given step 44 and the reference direction R should be between the first angle α1 and the second angle α2, that is, between the minimum angle formed on the one hand between the incident ray in the incident angle range 12 and the reference direction R, and on the other hand between the minimum angle formed between the refracted ray in the refraction angle range 30 and the reference direction R.

[0091] It should be noted that, in the context of the first embodiment, Figures 1 to 3 A light-emitting module 1 with incident rays 10 tilted downwards is shown; that is, each of these incident rays 10 forms an angle measured from the reference direction R to the incident ray 10, which is a positive angle. A more detailed description will now follow. Figures 5 to 8 The incident light rays 10 are depicted as upward-sloping rays within the light-emitting module 1; in other words, each of these incident light rays 10 forms an angle measured from the reference direction R to the incident light ray 10, which is a negative angle.

[0092] As mentioned above, regardless of whether the incident ray 10 is oriented downwards or upwards, an inequality is always satisfied. According to this inequality, the angle α of the step 44 lies between a first angle α1 formed between the first boundary 36 and the reference direction R, and a second angle α2 formed between the second boundary 42 and the reference direction R. However, the orientation of the incident ray 10 affects the orientation of the steps 44, which are substantially parallel to the incident rays 10, and therefore... Figures 5 to 8 In the case shown, these steps have an angle of inclination as the light tilts upward, such that if the step angle or draft angle is considered to start from the reference direction R, then the step angle or draft angle is a negative angle.

[0093] Figure 5 and Figure 6 This schematically provides a better understanding of the benefits of satisfying the inequality regarding incident ray 10, while Figure 7 and Figure 8 This schematically provides a better understanding of the benefits of satisfying the inequality regarding refracted rays 28.

[0094] therefore, Figure 5 This demonstrates the case where the angle α between step 44 and reference direction R is correctly chosen relative to the angle measured between one of the incident rays 10 and reference direction R (this angle corresponds here to the first angle α1). Conversely, Figure 6This demonstrates the situation where the choice of angle α between step 44 and reference direction R is inappropriate compared to the first angle α1.

[0095] Similarly, for refracted ray 28, Figure 7 This illustrates the case where the angle α between step 44 and the reference direction R is correctly chosen relative to the second angle α2 measured between one of the refracted rays 28 and the reference direction R. Figure 8 This illustrates a situation where the choice of step angle α is unsuitable relative to the second angle α2. From the foregoing, it will be understood that... Figure 5 and Figure 7 Corresponding to the case where the light-emitting module 1 correctly performs its light function by satisfying the inequality unique to this invention, according to this inequality, the angle α is between the angle α1 of the first boundary 36 and the angle α2 of the second boundary 42, and conversely, Figure 6 and Figure 8 The case where the inequality is not satisfied is shown, and the resulting stray light is shown, which can easily cause the light-emitting module 1 to malfunction.

[0096] exist Figure 5 In this context, the angle α measured between step 44 and the reference direction R is smaller than the angle α1 measured between the first boundary 36 and the reference direction R. It should be noted that the first boundary 36 corresponds to the first extreme incident ray 32, which forms the angle with the reference direction R with the smallest absolute value. Therefore, the incident ray 10 reaching the main incident surface 16 of the microlens array device 6 cannot enter the microlens array device 6 via step 44, thereby preventing the formation of stray rays. All incident rays 10 enter the microlens array device 6 via one of the incident surfaces 24, and almost all incident rays 10 are refracted by these incident surfaces 24 to propagate through the dedicated optical channels.

[0097] On the contrary, Figure 6 In this context, the angle α measured between step 44 and the reference direction R is greater than angle α1. Therefore, the angle of the step at this point is unsuitable because the incident light ray 10 can enter the microlens array device 6 via step 44. This ease of entry of light ray via step 44 (in...) Figure 6 (Shown as white arrows) This is undesirable because they are not properly aligned with the incident surface 24 of one of the incident microlenses 20, and they subsequently propagate in a direction that does not conform to the desired propagation direction, i.e., they do not converge toward the exit surface associated with the incident surface. In this respect, these rays entering via step 44 pose a risk of interfering with the formation of a uniform beam 100 that complies with regulations, and thus hinder the implementation of the light functions performed by the light-emitting module 1.

[0098] Therefore, when the inequality that angle α is less than angle α1 is not satisfied, the light-emitting module 1 is prevented from working satisfactorily.

[0099] exist Figure 7 In this context, the angle α measured between step 44 and the reference direction R is greater than the angle α2 measured between the second boundary 42 and the reference direction R. It should be noted that the second boundary 42 corresponds to the second extreme refracted ray 40, which forms the angle with the reference direction R with the smallest absolute value. Therefore, the tilt angle of step 44 is sufficiently wide to prevent the refracted ray 28, which has entered the microlens array device 6, from directly encountering step 44 after its refracted incident surface. Thus, total internal reflection of the refracted ray 28 on step 44 is advantageously prevented.

[0100] However, in Figure 8 In this context, the angle α measured between step 44 and the reference direction R is less than angle α2. Therefore, the step angle α is unsuitable because some refracted rays in refracted ray 28, especially those with a refraction angle α2, are prone to encountering step 44 and thus undergoing total internal reflection. Figure 8 In the image, the refracted light 28, which undergoes total internal reflection within the microlens array device 6 after illuminating step 44, is shown as a white arrow. The formation of such light within the light-emitting module 1 is undesirable because it risks negatively impacting the quality of the light beam 100 and thus the light function implemented by the light-emitting module 1.

[0101] Therefore, when the inequality that angle α is greater than angle α2 is not satisfied, the light-emitting module 1 is prevented from working satisfactorily.

[0102] According to the invention, it is therefore sought that at least one step 44 (and, if possible, all steps) is configured to have a draft angle, i.e., an angle α between the step and the reference direction R, which satisfies the following inequality: α1 < α < α2, in α: The angle between step 44 and the reference direction R, equivalent to the draft angle. α1: The first limit 36 ​​of the incident angle range 12 is defined by the angle relative to the reference direction R. α2: The second limit 42 that defines the range of refraction angles 30° relative to the reference direction R.

[0103] In the context of the embodiment shown relative to light source 2 (i.e., for the microlens array device 6 where the incident surface 24 is offset according to an increasing monotonic function that tends to bring the incident surface 24 closer to the collimator as the distance from the optical axis O increases), for an incident ray 10 forming a positive angle with respect to the reference direction R, i.e., a downward-sloping incident ray 10, step 44 corresponds to an increase in material relative to the straight optical channel 14 (i.e., an optical channel substantially parallel to the reference direction R). Therefore, step 44 follows the positive tilt angle of the incident ray 10. Similarly, when the incident surface 24 is offset according to an increasing monotonic function but the incident ray 10 forms a negative angle with respect to the reference direction R (i.e., an upward-sloping incident ray 10), Figure 4 The same applies to incident rays 10 from the auxiliary light source 8. Steps 44 correspond to the added material relative to the straight optical path 14. Conversely, in cases not shown here (where the incident surface 24 of the microlens array device 6 is offset according to a decreasing monotonic function that tends to move the incident surface 24 away from the collimator as the distance from the optical axis O increases), incident rays 10 at a positive angle relative to the reference direction R will produce steps 44, which will correspond to the material removed relative to the straight optical path 14.

[0104] The incident and refracted rays shown in the attached diagram correspond to certain specific configurations. For example, in Figure 2 In this configuration, the incident rays are located within a downward tilt angle range, and the refracted rays are located within an upward tilt angle range. In other words, when considered in the direction of light propagation, all incident rays are oriented downwards, and all refracted rays are oriented upwards. However, other configurations are possible. For example, the incident rays can be located within an angular range distributed around the reference direction R. Thus, some incident rays are downward tilted, while others are upward tilted. In other words, the two extreme incident rays 32 and 34 of the angular range are distributed on either side of the reference direction R, meaning that one extreme incident ray forms a positive angle relative to the reference direction R, while the other extreme incident ray forms a negative angle relative to the reference direction. Similarly, the refracted rays can be located within an angular range distributed around the reference direction R. Furthermore, the incident rays can also be located within an upward tilt angle range. Additionally, the refracted rays can also be located within a downward tilt angle range.

[0105] exist Figure 2 In the accompanying diagram, the propagation of light rays is oriented from right to left, meaning the optical axis O is oriented from right to left in the positive direction of the diagram, and the same applies to the reference direction. This orientation is used here, and these angles are measured in trigonometric directions (and counterclockwise).

[0106] exist Figure 2In this configuration, each of the two extreme incident rays 32 and 34 forms a positive angle with the reference direction R. As can be seen above, the angle formed by the first extreme incident angle 32 and the reference direction R is smaller than the angle formed by the second extreme incident angle 34 and the reference direction R.

[0107] Similarly, as seen above, the angle formed by the first extreme refracted ray 38 and the reference direction R is greater than the angle formed by the second extreme refracted ray 40 and the reference direction R; that is, the absolute value of the angle of the first extreme refracted ray 38 is greater than the absolute value of the angle of the second extreme refracted ray 40. However, since both angles are negative, when considering their real values, the angle of the first extreme refracted ray 38 is smaller than the angle of the second extreme refracted ray 40.

[0108] Therefore, generally speaking, the incident angle range has a lower limit formed by the first extreme incident ray 32 and an upper limit formed by the second extreme incident ray 34. Each of these angular limits can have a positive or negative value, or one of these angular limits can be zero, that is, the corresponding extreme incident ray is parallel to the reference direction R.

[0109] Similarly, generally speaking, the range of refraction angles has a lower limit formed by the first extreme refracted ray 38 and an upper limit formed by the second extreme refracted ray 40. Each of these angular limits can have a positive or negative value, or one of these angular limits can be zero, that is, the corresponding extreme refracted ray is parallel to the reference direction R.

[0110] Therefore, the angle formed by step 44 and the reference direction R must lie between the first limit 36 ​​and the second limit 42. The first limit is called the upper limit, corresponding to the lower limit of the incident angle, and the second limit is called the lower limit, corresponding to the upper limit of the refraction angle. For this reason, the lower limit of the incident angle should be greater than the upper limit of the refraction angle.

[0111] This holds true when the incident microlenses 20 forming the step 44 are offset relative to each other, such that the incident microlens located above the step 44 is placed behind the incident microlens located below the step 44 in the direction along the optical axis O.

[0112] In the case where the incident microlenses 20 forming the step 44 are offset relative to each other, such that the incident microlens located above the step 44 is positioned in front of the incident microlens located below the step 44 in the direction along the optical axis O, this description is consistent with... Figure 2 The vertical symmetry is similar. For example, a positive value becomes a negative value, and vice versa, and the lower limit becomes the upper limit, and vice versa.

[0113] It should be noted that when the microlens array device is made of injectable plastic, it can be demolded along an axis forming a non-zero angle with the optical axis O. Therefore, the draft angle relative to this inclined demolding axis must be sufficiently large, and the orientation of step 44 relative to the reference direction R still conforms to the angular range defined above. However, the microlens array device can also be manufactured using processes other than injection molding, particularly processes that do not require a draft angle relative to the demolding angle. In this case, as described above, the orientation range of step 44 relative to the reference direction R remains valid.

[0114] Therefore, the present invention provides a light-emitting module including a microlens array device, wherein a step is provided between adjacent incident microlenses to impart a curved profile to the microlens array device, the step being configured to have a predefined angle that simultaneously solves two optical problems: because the inclination angle of the step limits stray light and manufacturing problems related to demolding the microlens array device from the mold, the angle of the step allows the microlens array device to be demolded from the mold without difficulty.

[0115] However, the invention is not limited to the devices and configurations described and shown herein, but extends to any equivalent devices and configurations and any technically operable combinations of such devices.

Claims

1. A light-emitting module (1) for a motor vehicle, the light-emitting module being configured to project at least one light beam along the optical axis (O) of the light-emitting module (1), the light-emitting module (1) comprising at least one light source (2), a collimator (4), and a microlens array device (6), the light source (2) being configured to emit light toward the microlens array device (6) through the collimator (4), the microlens array device (6) comprising: The light-emitting module (1) comprises a main incident surface (16) designed to receive incident light rays (10) from the light source (2) and which have passed through the collimator (4); a main exit surface (18) disposed opposite to the main incident surface (16); and a plurality of optical channels (14) including an incident microlens (20) and an exit microlens (22), each optical channel (14) being defined by an incident surface (24) participating in the formation of the main incident surface (16) and an exit surface (26) participating in the formation of the main exit surface (18), the light-emitting module (1) being configured such that each incident light ray (10) received by the main incident surface (16) is within an incident angle range (12), and such that the light passes through the collimator (4). The main incident surface (16) refracts each ray propagating in the direction of the main exit surface (18) within the optical channel within the refraction angle range (30). At least some of the incident microlenses (20) are offset from other incident microlenses to form a step (44) between two adjacent incident microlenses (20). At least one step (44) is configured such that the angle (α) between the step (44) and the reference direction (R) of the light-emitting module (1) falls between a first limit (36) defining the incident angle range (12) relative to the reference direction (R) and a second limit (42) defining the refraction angle range (30) relative to the reference direction (R).

2. The light-emitting module (1) as described in the preceding claim, wherein, The first limit (36) corresponds to the incident ray (32, 34) closest to the reference direction (R) in the incident angle range (12), and the second limit (42) corresponds to the refracted ray (38, 40) closest to the reference direction (R) in the refraction angle range (30).

3. The light-emitting module (1) as described in any of the preceding claims, wherein, The incident surface (24) of the optical channel (14) is offset relative to each other in a direction parallel to the reference direction (R).

4. The light-emitting module (1) as described in the preceding claim, wherein, The incident surface (24) of the optical channel (14) is shifted according to a monotonic function.

5. The light-emitting module (1) as described in any of the preceding claims, wherein, The incident surfaces (24) of the optical channel (14) are arranged symmetrically around an axis parallel to the reference direction (R).

6. The light-emitting module (1) as described in any of the preceding claims, wherein, At least some of the steps arranged between the incident surfaces of the microlens array device, which are intended to receive incident light from the same light source, are parallel to the other steps.

7. The light-emitting module (1) as described in any of the preceding claims, wherein, At least some of the optical channels (14) have a thickness (E) different from the thickness of the other optical channels, and the thickness (E) of the optical channel is measured between the incident surface (24) and the exit surface (26) of the optical channel.

8. The light-emitting module (1) as claimed in any of the preceding claims, comprising an additional light source (8), wherein the incident light ray (10) from the light source (2) and the incident light ray (10) from the additional light source (8) have different incident angles at the exit of the collimator (4).

9. The light-emitting module (1) of the preceding claim includes a partition (13) disposed between the incident light (10) from the light source (2) and the incident light (10) from the additional light source (8).

10. The light-emitting module (1) as described in any one of claims 8 and 9, wherein, At least some of the incident surfaces (24) of the optical channel (14) receiving the incident light rays (10) from the additional light source (8) are offset relative to other incident surfaces in a direction parallel to the reference direction (R). These incident surfaces (24) are offset according to a monotonic function. The monotonic function followed by the incident light rays (10) received by the incident surface (24) from the light source (2) is different from the monotonic function followed by the incident light rays (10) received by the incident surface (24) from the additional light source (8).

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