Carrier for a light emitting unit movable relative to a projection lens in a light module for a motor vehicle and method of manufacture

Abstract

The invention relates to a load carrier (34) comprising a plurality of baffles (36) and a frame (38) extending along a main direction of elongation, said baffles (36) being rotatable relative to the frame (38) about a pivot axis perpendicular to the main direction of elongation, characterized in that the baffles (36) and the frame (38) form an integral assembly and that each baffle (36) is secured to the frame (38) by a first resilient hinged connection at the joint between said baffle (36) and a first wall (42) of the frame (38) and by a second resilient hinged connection at the joint between said baffle (36) and a second wall (44) of the frame (38), the first and second resilient hinged connections defining the pivot axis.

Description

[0001] This invention relates to the field of light-emitting modules, and more particularly to light-emitting modules intended to be equipped in motor vehicles. More specifically, this invention relates to a support for supporting a light-emitting unit housed within a housing of such a light-emitting module, the light-emitting unit being capable of generating light rays exiting the light-emitting module through a projection lens fixed relative to the housing, and the light-emitting unit being movable relative to the housing.

[0002] Vehicles, especially motor vehicles, are typically equipped with headlights that enable various luminous functions, such as illuminating the road or signaling the presence of a vehicle. To this end, motor vehicle headlights are equipped with light-emitting modules, each including at least one light source configured to emit light, optical elements associated with the at least one light source for collecting and directing the light, and at least one projection lens configured to shape the light collected and directed by the optical elements and project it toward the headlight and the external environment of the motor vehicle, thereby forming a compliant beam suitable for performing the luminous function.

[0003] The light-emitting function, and especially the illumination function, must be properly adjusted to provide optimal road lighting while limiting unpleasant glare to other road users. These adjustments may be made, for example, on the assembly line when the light-emitting module is installed in the headlight, or automatically based on information obtained from sensors placed on the vehicle during vehicle movement.

[0004] Therefore, the beam can be adjusted to have both vertical and lateral propagation ranges. Vertical propagation range is a useful way to take into account the vehicle's attitude (which varies between different vehicle classes and depends on the vehicle's load) and to reduce the beam's intensity to avoid causing discomfort or glare to occupants of oncoming vehicles. Lateral propagation range is a useful way to adjust the two light-emitting modules to each other and ensure good alignment of the beams relative to the vehicle's axis.

[0005] Especially for reasons of size or even aesthetics, it may be desirable to have a projection lens that remains fixed during vertical and horizontal adjustment of the beam. However, in the context of a fixed projection lens and a light-emitting unit (including at least one light source and optical element) that can move relative to the projection lens, it is necessary to ensure that at least one light source and optical element remain in a relative position relative to the projection lens that allows the light-emitting function to be performed.

[0006] To address this, a known approach is to provide a carrier configured to support the light-emitting unit and pivotally mounted relative to the housing of the light-emitting module, within which the light-emitting unit is housed. While this configuration is effective because it allows the light-emitting unit to be moved to adjust the beam while ensuring that at least one light source and optical element remain correctly positioned relative to the projection lens, its disadvantages include the complexity of assembling the light-emitting unit with the carrier and the increased maneuvering required by the operator when mounting the light-emitting unit into the housing.

[0007] The present invention falls within this context and aims to overcome at least some of the disadvantages of the prior art, and in particular to provide an architecture for a pivot carrier for a light-emitting unit that allows for easier assembly of the light-emitting module, in which the carrier and the light-emitting unit are combined.

[0008] Therefore, the first subject of the present invention is a support member intended to support a light-emitting unit within a housing of a motor vehicle light-emitting module. The support member includes a plurality of baffles and a frame, the baffles being configured to define between them at least one channel for distributing light emitted by the light-emitting unit. The frame extends in a main extension direction, and the baffles are rotatably movable relative to the frame about a front pivot axis perpendicular to the main extension direction. The baffles extend in a main extension direction secant from the main extension direction of the frame, and each baffle includes an anchoring end on the opposite side of the frame, the anchoring end being intended to interact with the light-emitting unit. The baffles and the frame form an integral assembly, and each baffle is secured to the frame by a resilient hinge connection. A first resilient hinge connection is formed at a junction of the baffle and a first wall of the frame, and a second resilient hinge connection is formed at a junction of the baffle and a second wall of the frame. The front pivot axis is defined by the alignment of the first and second resilient hinge connections.

[0009] A carrier is a structural element that allows the light-emitting unit to be carried within the light-emitting module. This carrier allows the light-emitting unit to move relative to the housing of the light-emitting module, particularly to allow adjustment of the position of the light-emitting unit within the housing, and to allow adjustment of the orientation of the light beam exiting the light-emitting module. Therefore, it should be understood that the carrier allows the light-emitting unit to be both held in place and moved within the housing. More specifically, the light-emitting unit is allowed to move in two adjustment directions, thereby allowing adjustment of the orientation of the light beam emitted by the light source housed within the light-emitting unit.

[0010] In the carrier according to the invention, the first elastic hinge connection and the second elastic hinge connection respectively form the hinge area of ​​the corresponding baffle. Therefore, the hinge axis, referred to here as the front pivot axis, can be defined by aligning these elastic hinge connections.

[0011] The frame and baffles of the load-bearing member form an integral assembly, such that each baffle is integrally formed with the frame, and more particularly with the frame segment supporting the baffle. Each of the resilient hinge connections formed at the joint between the baffle and the wall of the frame consists of a weakened region that allows the baffle to pivot about the weakened region when subjected to stresses, for example, induced by an adjusting device. The alignment of the two weakened regions associated with a given baffle contributes to forming the front pivot axis of the baffle about which the baffle pivots relative to the frame of the load-bearing member.

[0012] This pivot axis is referred to here as the front pivot axis because the free end or anchored end of the baffle is designed to interact with the light-emitting unit to form a rear pivot axis that is substantially parallel to the front pivot axis for each baffle.

[0013] It should be noted that the front pivot axis is perpendicular to, or substantially perpendicular to, the main extension direction of the frame, because the angle can vary by ±5°. Specifically, the projection lens may, in some cases, have an aesthetic tilt of up to 5° that the frame will follow, the light-emitting module is equipped with this projection lens, and light can exit the light-emitting module through this projection lens. Then, the front pivot axis will form a slight tilt with the main extension direction of the frame, depending on the tilt of the projection lens. However, independent of the tilt of the projection lens, each front pivot axis of the baffle is perpendicular to the optical axis of the projection lens.

[0014] In the carrier according to the invention, the carrier advantageously comprises an integrally formed frame and baffles, which facilitates the overall assembly of the light-emitting module because the operator does not have to perform the tedious step of positioning each baffle relative to the frame. Furthermore, eliminating the need to position the baffles relative to the frame avoids the need to check whether the baffles are correctly positioned relative to each other before the light-emitting unit assembly is completed.

[0015] Therefore, the size of the weakened area was determined to achieve a compromise between the following two aspects: on the one hand, a narrow section is required to allow the baffle to pivot when subjected to stress of a predefined magnitude; on the other hand, the connection needs to be robust enough to support the weight of the baffle without causing the baffle to pivot relative to the frame under its own weight.

[0016] In this context, the baffles are able to maintain their theoretical orientation relative to the main elongation direction of the frame during assembly. This orientation is important because the free ends of the baffles on the opposite side of the frame are designed to be fastened to the light-emitting unit.

[0017] According to one feature of the invention, a first resilient hinge connection and a second resilient hinge connection associated with the baffle are formed at each of the joints of the two opposing walls of the baffle and the frame. Corresponding weakened areas are formed on the opposing edges of the baffle and near the respective walls in the frame.

[0018] According to one feature of the invention, each of the resilient hinge connections is formed by at least one gap, which is configured to form a thin region at the junction between the baffle and one of the walls of the frame.

[0019] As already mentioned, each baffle extends in the main extension direction, and the thickness corresponds to the size of the baffle, which is measured in a direction perpendicular to the main extension direction of the baffle and perpendicular to the front pivot axis associated with the baffle.

[0020] The thin region here must be understood as a segment of the baffle whose thickness is reduced compared to the rest of the baffle. This thin region locally reduces the cross-section of the baffle perpendicular to the front pivot axis. Therefore, the flexible hinge connection forms discrete points where the baffle pivots relative to the frame.

[0021] According to one feature of the invention, the thickness of the baffle is locally reduced to form a resilient hinge connection in the main extension direction of the baffle and in the direction of the front pivot axis. Specifically, the resilient hinge connection does not extend the entire length of the baffle's height, i.e., the dimension of the baffle parallel to the front pivot axis. The thickness of the baffle is reduced discretely only at the joints of the baffle and each wall of the frame, rather than across the entire height of the baffle, to facilitate the formation of the resilient hinge connection via a molding process. Specifically, this allows for adherence to the draft angle required for partial demolding and control of the desired thickness in the thin region, i.e., the thickness compared to the rest of the baffle, as described above, which is small enough to produce a bend as the starting point of the pivoting movement, but has a minimum value that allows the baffle to be held in its theoretical position when it is not subjected to stress from the movement of the light-emitting unit via the adjustment system.

[0022] According to one feature of the invention, at least one gap is formed as a recess within the thickness of one of the walls of the frame. The gap is created such that the thin region of the baffle and the recess are continuously formed. In particular, the gap is defined by an arcuate shape with a given radius of curvature. It should be understood that, here, at least one gap formed at the junction of the baffle and the wall of the frame includes a gap forming a recess within the wall of the frame and a gap forming a thin region within the baffle.

[0023] According to one feature of the invention, each of the resilient hinge connections is formed by a first gap and a second gap, said gaps being separated by a thin region. The first gap and the second gap are formed on both sides of the baffle, more specifically on both sides of the thin region and the front pivot axis. Forming a gap on each side of the baffle allows the baffle to pivot relative to the frame in two pivot directions.

[0024] According to one feature of the invention, the first gap and the second gap have the same radius of curvature. Making the first gap and the second gap have the same radius of curvature increases the uniformity of stress experienced by the baffle in each of the pivoting directions.

[0025] According to one feature of the invention, a baffle may be parallel to a movable front pivot axis relative to the frame, and another baffle may be parallel to a movable front pivot axis relative to the frame, at least one other front pivot axis. The design of the load-bearing member according to the invention (where the baffle is integrally formed with the frame) makes it possible to avoid the operation of assembling the baffles one by one with the frame, which (besides being difficult) would result in multiple installation gaps that could affect the desired parallelism of the pivot axes.

[0026] According to one feature of the invention, when the baffle is unstressed and in its nominal position, the baffle's principal extension direction is inclined relative to a direction perpendicular to the principal extension direction of the frame, and also inclined relative to a direction perpendicular to the front pivot axis. Since the gaps are arranged symmetrically with respect to the baffle's principal extension direction, the inclination of the baffle relative to the frame's normal means that one of the gaps forms a large recess in one wall of the frame. The inclination of the baffle results in a tilt angle between the baffle's principal extension direction and the frame's principal extension direction that is strictly greater than 0°, preferably less than 20°.

[0027] According to one feature of the invention, the first wall of the frame is an upper wall, and the second wall of the frame is a lower wall, the upper wall and the lower wall being opposite each other. The upper wall is secured to the baffle by a first resilient hinge connection, and the lower wall is secured to the baffle by a second resilient hinge connection. The upper wall and the lower wall are separated such that light emitted by at least one light source passes between the upper wall and the lower wall to reach the projection lens. It should be recalled that each resilient hinge connection is located near the junction of the baffle and one of the walls of the frame, and therefore it should be understood that the distance between the first resilient hinge connection and the second resilient hinge connection is substantially equal to the distance separating the upper wall and the lower wall. Furthermore, it should be understood that the resilient hinge connections form discrete connections and do not extend the entire length of one dimension of the baffle.

[0028] According to one feature of the invention, at least one baffle includes a light-shielding section extending between the lower wall and the upper wall of the frame. The light-shielding wall allows for the extension of at least one guide channel. Therefore, light passing through the guide channel is guided through that channel to the projection lens, and cannot join another guide channel.

[0029] According to one feature of the invention, the baffle includes a central segment that participates in defining a guide channel, the central segment extending between a joint area of ​​the baffle connecting frame and an anchoring end of the baffle, and a light-shielding segment extending the central segment in the main extension direction of the baffle, extending beyond the joint area.

[0030] According to one feature of the invention, each of the plurality of baffles extends parallel to the other baffles.

[0031] According to one feature of the invention, the frame and the baffle are formed of the same material.

[0032] According to one feature of the invention, the frame and baffle are formed of polyoxymethylene (POM). POM is also known as polyoxymethylene.

[0033] According to one feature of the invention, the carrier includes tilting elements at each lateral end of the carrier, the tilting elements being aligned to define a tilt axis, and the carrier being pivotally mounted relative to a projection lens of a light-emitting module on which the carrier is mounted, about the tilt axis. The tilting elements may be in the form of lugs.

[0034] The second subject of the present invention is a motor vehicle light-emitting module, which includes a carrier according to at least one of the features presented above.

[0035] According to one feature of the present invention, the light-emitting module includes: - Casing; - A projection lens, which is fixed relative to the housing; - A light-emitting unit, which contains at least one light source, and the light emitted by the at least one light source can be projected by the projection lens along the optical axis of the light-emitting module. The light-emitting unit can move relative to the projection lens in an adjustment direction. - The multiple baffles of the carrier are each connected to the light-emitting unit via their anchoring ends. These baffles are configured to define at least one channel for guiding light emitted by the at least one light source along the direction of the projection lens. The anchoring end of each of these baffles is pivotally mounted relative to the light-emitting unit about a rear pivot axis, and Each of these baffles is connected to the frame of the load-bearing member via a resilient hinge connection that defines the front pivot axis. The front pivot axis and the rear pivot axis are parallel to each other, and for each of these baffles, the distance between the front pivot axis and the rear pivot axis is the same. The front pivot axis and the rear pivot axis allow the light-emitting unit to move perpendicular to the front pivot axis and the rear pivot axis and substantially perpendicular to the optical axis in the adjustment direction.

[0036] According to one feature of the invention, the carrier supports the light-emitting unit and is pivotally mounted relative to the projection lens about a tilt axis, so as to allow the light-emitting unit to move in a correction direction, which is different from the adjustment direction.

[0037] The light-emitting module includes a fixed projection lens and a light-emitting unit movable relative to the housing. The light-emitting unit includes one or more light sources configured to emit light, and may include optical elements for shaping the light. The optical elements allow light emitted by the one or more light sources to be directed through the projection lens. For example, the optical elements may be configured to collect, guide, and deflect light emitted by the light sources toward the projection lens of the light-emitting module. In particular, the light-emitting unit may not have a lens. Therefore, only the projection lens of the light-emitting module allows light emitted by one or more light sources to be projected onto the road.

[0038] A projection lens is an element of a light-emitting module through which light can exit the module and be projected in the direction of a road. Therefore, the projection lens is configured to shape light emitted by at least one light source, optionally collected and directed by one or more optical elements of the light-emitting unit, and project this light toward the external environment of the light-emitting module. The projection lens is an element that processes light to conform to various regulations. More specifically, the projection lens particularly enables the modification of the path of light emitted by the light-emitting unit, which is first directed, where appropriate, by one or more optical elements placed in the light-emitting unit, upstream of the projection lens, to generate a light beam with desired parameters.

[0039] As will be understood from the above, a projection lens is an optical element that functions in performing the light-emitting function by light rays passing through it, and without a projection lens, it would be impossible to produce a compliant light beam. In other words, a projection lens should not be confused with a transparent outer lens, which is designed to form a mechanical protective element for the optical device housed in the headlight and does not involve any specific optical processing of the light rays to achieve compliant light emission.

[0040] Furthermore, the projection lens is placed at a certain distance from the light-emitting unit and does not form part of the light-emitting unit. For example, the projection lens is configured such that when the light-emitting module is assembled, the object-side focal point of the projection lens is located at the light-emitting unit, for example, at the light source of the light-emitting unit, or at an optical element inserted between the light source and the projection lens. More precisely, the light-emitting unit may include a light collector and at least one light source, the reflective surface of which allows light generated by the light source to be guided in the direction of the projection lens. The object-side focal point of the projection lens is placed less than 10 mm from the rear edge of the light collector (i.e., the edge furthest from the projection lens).

[0041] The light-emitting module is associated with a device for adjusting the position of the light-emitting unit. The adjusting device allows the light-emitting unit to move in a correction direction or an adjustment direction. In particular, the adjusting device can move the light-emitting unit in a substantially vertical or substantially horizontal direction by pushing a given portion of the light-emitting unit to allow the light-emitting unit to move in the correction direction or the adjustment direction.

[0042] According to one feature of the invention, the light-emitting module includes a lateral adjustment device configured to pivot the baffle about its respective front pivot axis in the adjustment direction.

[0043] According to one feature of the invention, the light-emitting module includes a vertical adjustment device configured to pivot the light-emitting unit relative to the housing about a tilt axis in a correction direction. More specifically, the correction direction is generated by the tilting of the support member about the tilt axis.

[0044] The adjustment direction is generated by the pivoting of the baffle about the front and rear pivot axes. The correction direction is defined by the orientation of the tilt axis of the carrier, which is perpendicular to the tilt axis. The correction direction ensures vertical adjustment of the beam formed by the light source and projected by the light-emitting module. It should be understood that this vertical adjustment allows for greater or lesser orientation of the beam toward the road in which the vehicle equipped with the light-emitting module is traveling. The adjustment direction is defined by the orientation of the pivot axis of the baffle. Specifically, the adjustment direction is perpendicular to the pivot axis. In addition, the adjustment direction is also substantially perpendicular to the optical axis. It is the movement of the baffle about its front pivot axis that allows the light-emitting unit to move in the adjustment direction. For example, if the pivot axis is vertical, the light-emitting unit can move laterally in the horizontal plane. The adjustment direction ensures horizontal adjustment of the beam. Therefore, this horizontal adjustment allows for greater or lesser orientation of the beam toward one of the two sides of the road adjacent to the road.

[0045] As described above, the tilting elements placed at each lateral end of the carrier define a tilting axis, around which the carrier is pivotally mounted relative to the projection lens of the light-emitting module. The tilting axis can be parallel to the adjustment direction. However, it will also be understood that the tilting axis can be at an angle to the adjustment direction. In a particular case, the tilting axis can be parallel to the lateral direction.

[0046] In particular, it should be understood that an angle strictly greater than 0° and less than or equal to 20° between the adjustment direction and the tilt axis is possible, especially to allow the tilt axis to not necessarily be parallel to the adjustment direction (including the lateral adjustment direction). Specifically, particularly for aesthetic reasons, when viewed from above, it may be necessary to tilt the projection lens to conform to the curvature of the vehicle body, and the tilt axes of the carrier and the light-emitting unit must be tilted by the same amount. Here, the adjustment direction corresponding to the lateral adjustment direction thus intersects the direction of the tilt axis.

[0047] The function of the baffle is to guide the light emitted by the light source along the direction defined by the projection lens. The carrier participates in defining multiple guide channels. Among these guide channels, two guide channels, referred to as end guide channels, are defined by a portion of the housing and the baffle, and at least one other guide channel located between these end guide channels is defined by two baffles. It should be understood that when the carrier participates in defining only three guide channels, each baffle participating in defining the end guide channels also participates in defining the guide channel located between the end guide channels.

[0048] In this situation, and especially when the light-emitting unit is laterally offset, the light guiding channel needs to remain properly oriented to continue delivering light to the appropriate segment of the projection lens. For this purpose, a baffle is fastened to the light-emitting unit at a first end (called the anchoring end), particularly to the upper and lower portions of the light-emitting unit, which also contribute to defining the guiding channel.

[0049] In this context, it is worth noting that the production of the carrier according to the invention (where the baffle forms an integral part of the carrier due to being integrally formed with the frame supporting the tilting element) allows the position of the front pivot axis of the baffle to be set independently of the assembly of the light-emitting module, especially the mounting gap inherent in the assembly of the light-emitting unit relative to the carrier.

[0050] According to one feature of the invention, the light-emitting unit is formed by a first portion, at least partially formed by a reflective device, and a second portion, at least partially formed by a heat dissipation device. The first portion of the light-emitting unit is configured to reflect light emitted by at least one light source housed in the light-emitting unit along the direction of a projection lens, through which the light can exit the light-emitting module. It should be noted that, without departing from the context of the invention, the function of each of the portions forming the light-emitting unit can be reversed.

[0051] According to one feature of the invention, each baffle is connected to a light-emitting unit, wherein the anchoring end of the baffle engages with each of the portions forming the light-emitting unit.

[0052] According to one feature of the invention, the baffle has finger-like portions extending in a direction parallel to the front pivot axis at the anchoring end on the opposite side of the frame, at least one of the finger-like portions of the baffle is fitted into a cavity formed in a first part of the light-emitting unit, and the other of the finger-like portions is fitted into a cavity formed in a second part of the light-emitting unit.

[0053] In other words, the baffle includes a central section and finger-like portions. The central section extends in the main extension plane between the engagement area with the frame of the support member and the anchoring end that interacts with the light-emitting unit. The finger-like portions protrude from the central section in a direction parallel to the directions of the front pivot axis and the rear pivot axis.

[0054] According to one feature of the invention, the carrier extends between the projection lens and the light-emitting unit, wherein the front edge faces the projection lens and the rear edge faces the light-emitting unit. The rear edge is the edge to which the baffle is connected.

[0055] The present invention also relates to a method for manufacturing a carrier, the method being carried out as follows: - At least in the first step, a cavity corresponding to the carrier is formed by juxtaposing the first, second and third portions of the mold; - At least a second step, in which material is injected into the cavity; - At least a third step, in which the first portion of the mold that participates in forming at least a first portion of each baffle is removed in a first demolding direction with a movement defined by a demolding vector of the first symbol; - At least a fourth step, in which the second portion of the mold that participated in forming at least a second portion of each baffle is removed in the first demolding direction by a movement defined by a demolding vector of a second symbol opposite to the first symbol; - At least a fifth step, in which the third portion of the mold that participates in forming at least a third portion of each baffle is removed in a second demolding direction perpendicular to the first direction.

[0056] It should be noted that there is no chronological order to follow regarding the three steps of removing a portion of the mold. For example, the term "first portion" is used only as an indication, and the word "first" does not imply that this portion of the mold must be removed before the other portions; the first portion of the mold can be removed after the second and / or third portions of the mold.

[0057] 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 numerous non-limiting examples of embodiments given in an illustrative manner in the accompanying drawings: [Figure 1 The diagram schematically shows an overall view of a light-emitting module according to the present invention, which includes a housing forming a protective sleeve for the light-emitting module, and a projection lens fixedly mounted on the housing; [ Figure 2 [Illustratively showing the contents contained in] Figure 1 An overall view of the light-emitting unit inside the housing of the light-emitting module shown; [ Figure 3 A schematic cross-sectional view of the light-emitting unit is shown, depicting guide channels separated from each other by baffles fixed at one end to a common support frame. [ Figure 4 ]Schematic illustration Figure 3 Details of the support frame and one of the baffles fastened to the support frame are shown; [ Figure 5 A schematic cross-sectional view of the light-emitting unit is shown, which illustrates... Figure 4 The arrangement of the baffle, which is fixed at one end to Figure 3 and Figure 4 The supporting frame, and at the other end interacts with the cavity formed in the light-emitting unit; [ Figure 6 The image schematically illustrates a carrier frame according to an alternative embodiment of the invention. Figure 6 The elastic hinged connection formed at the joint between the baffle and the load-bearing frame is shown; [ Figure 7 ]Schematic illustration Figure 6 The top view of the support member shown illustrates an elastically hinged connection formed via at least one gap, which creates a thin area at the joint between the baffle and the wall of the support member frame. [ Figure 8 [Illustratively shown according to] Figures 1 to 5 A detailed view of the first resilient hinge connection at the joint between the baffle and the wall of the support frame in the illustrated embodiment.

[0058] Features, variations, and various embodiments of the present invention can be associated with each other in various combinations, provided that they are compatible or non-exclusive. In particular, variations of the invention are contemplated to include only features selected below independently of 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.

[0059] In the following detailed description, the terms "longitudinal," "lateral," and "vertical" refer to the orientation of the light-emitting module including the carrier according to the invention. The longitudinal direction corresponds to the forward movement direction of the vehicle equipped with the light-emitting module, and is parallel to the longitudinal axis L of the reference frame (L, V, T) shown in the figures. The lateral direction corresponds to a direction in the horizontal plane perpendicular to the forward movement direction of the vehicle equipped with the light-emitting module, and is parallel to the lateral axis T of the reference frame (L, V, T), which is perpendicular to the longitudinal axis L. Finally, the vertical direction corresponds to a direction parallel to the vertical axis V of the reference frame (L, V, T), which is perpendicular to both the longitudinal axis L and the lateral axis T.

[0060] Figure 1 A light-emitting module 2 is shown. In the illustrated embodiment, a motor vehicle is intended to be equipped with this light-emitting module to perform a light-emitting illumination function, wherein a light beam is projected along an optical axis 100. The light-emitting module 2 includes a housing 4 forming a sheath, which will be referenced... Figure 2 The light-emitting unit, described in more detail, is housed within this housing. The housing 4 is formed of a polymer or metal. The housing 4 is intended to be housed in the headlight of a motor vehicle and has a fastening device (not depicted here) for this purpose. It should be noted that, in another embodiment of the invention, the housing 4 of the light-emitting module 2 is intended to be directly embedded into the body of a motor vehicle.

[0061] The housing 4 is formed by an upper portion 6 and a lower portion 8, which, in the illustrated embodiment, are fastened together by a screw-based fastening system 10 and a retaining device 11, with the screws advantageously positioned behind the light-emitting module 2. The retaining device 11 is formed by first connecting elements 12 and second connecting elements 14, the first connecting elements being formed on the edge of the upper portion 6 and the second connecting elements being formed on the edge of the lower portion 8 and complementary to the first connecting elements 12.

[0062] The light-emitting module 2 includes a projection lens 16, which is housed in the housing 4 and flush with the front of the housing 4 facing the road. This configuration allows the projection lens 16 to be placed in the extension of the vehicle body when the light-emitting module 2 is directly embedded in the vehicle body.

[0063] As will be understood from the foregoing, the projection lens 16 is fixed to the housing 4. More specifically, the position of the projection lens 16 relative to the housing 4 is fixed, and the tilt angle of the projection lens 16 relative to the housing 4 cannot be modified. Furthermore, the housing 4 is fixed relative to the headlight in which the light-emitting module 2 is housed, or, when the light-emitting module 2 is directly connected to the vehicle body, relative to that vehicle body.

[0064] Figure 2A light-emitting unit 18 is shown housed within a housing 4. The light-emitting unit 18 forms a enclosure that at least houses light sources (not shown here) capable of producing light emission, particularly illumination, to ensure visibility of the road, especially in very dark conditions, for vehicle occupants. These light sources produce the constituent rays of the light emission function, which are emitted from the light-emitting unit 18 along the direction of the projection lens 16.

[0065] The light-emitting unit 18 is associated with an adjustment device that allows modification of the position of the light-emitting unit within the housing 4 of the light-emitting module, and thus the position of the light-emitting unit relative to the fixed projection lens 16. Specifically, the light-emitting unit 18 can be moved relative to the projection lens 16 in a correction direction. The light-emitting unit 18 can also be moved relative to the projection lens 16 in an adjustment direction. In the example shown, the correction direction corresponds to the vertical adjustment direction, and the adjustment direction corresponds to the lateral adjustment direction.

[0066] like Figure 2 As shown, the light-emitting unit 18 is formed of two parts, namely a first part 20 and a second part 22, which are fastened to each other by means of at least one fastening element 24, which here takes the form of a resilient snap-fit ​​fastening device. In the example shown, the fastening element 24 is formed of a snap-fit ​​block 26 and a resiliently deformable tongue 28, the snap-fit ​​block being formed in the second part 22 of the light-emitting unit 18, and the resiliently deformable tongue being formed in the first part 20, the tongue being elastically deformable to engage with the snap-fit ​​block 26. It should be understood that, without departing from the context of the invention, the positions of the snap-fit ​​block and the tongue in the first and second parts can be interchanged, and other fastening elements (such as screw-based fastening devices) can be used.

[0067] The first portion 20 of the light-emitting unit 18 is at least partially formed by a reflective device. For this purpose, the first portion 20 includes a plurality of light collectors 30, which are configured to collect light emitted by at least one light source and guide the light along the direction of the projection lens 16.

[0068] The second portion 22 of the light-emitting unit 18 is at least partially formed by a heat dissipation device. For this purpose, the second portion 22 includes heat dissipation elements 32 that are capable of removing heat generated within the light-emitting unit 18, such as heat generated by the light source, and more broadly heat generated by the printed circuit board housed in the light-emitting unit 18 and including multiple electronic components involved in the operation of the light-emitting unit 18.

[0069] The light-emitting module 2 also includes a carrier 34, which is pivotally mounted relative to the housing 4 and thus relative to the projection lens 16, and is configured to support the light-emitting unit 18 within the housing 4. The carrier 34 includes a frame 38 and a plurality of baffles 36. Figure 2 In the middle, only a portion of the baffles 36 are visible, each of the baffles 36 being configured to define at least one channel 40 for guiding some of the light emitted by one of the light sources.

[0070] More specifically, the light-emitting unit 18 includes a plurality of guide channels 40, which are defined by at least one baffle 36 and a first portion 20 and a second portion 22 of the light-emitting unit 18. In the illustrated embodiment, the carrier 34 includes three baffles 36 that participate in defining the four guide channels 40. Each guide channel 40 allows light emitted by the light source to be guided to the projection lens 16.

[0071] For reference Figure 3 and Figure 4 In more detail, each baffle 36 is secured to the light-emitting unit 18 at one end of its end and connected to the frame 38 at the other end of its end in the engagement area, which will be detailed below.

[0072] Frame 38 extends in the main elongation direction, in Figure 2 In the illustrated embodiment, the main elongation direction is substantially parallel to axis T. Frame 38 includes a first wall 42, here the upper wall, and a second wall 44, here the lower wall. The first wall 42 and the second wall 44 are connected at their lateral ends by side walls. The first wall 42 and the second wall 44 are opposite to each other and each extends primarily along the main elongation direction of frame 38, thus facing each other.

[0073] A first wall 42 and a second wall 44 of frame 38 are connected at each end of frame 38, these ends being defined by sidewalls relative to the main elongation direction, each sidewall supporting a lug forming a tilting element. More specifically, frame 38 extends between a first lug 46 and a second lug 48, which respectively extend along the main elongation direction of frame 38. More precisely, the first lug 46 and the second lug 48 extend from their respective sidewalls toward the external environment of frame 38. The first lug 46 and the second lug 48 are aligned relative to each other to define a tilting axis 50 about which the carrier 34 is rotatably movable. It should be understood that since the support member 34 is fixed to the light-emitting unit 18 as long as the baffle 36 of the support member 34 is engaged in the appropriate cavity of the light-emitting unit 18, the light-emitting unit 18 can also pivot about the tilt axis 50 when the support member 34 is driven by the support member 34, as the first lug 46 and the second lug 48 rotate in the bearing formed between the upper part 6 and the lower part 8 of the housing 4 respectively.

[0074] More specifically, such as Figure 3 As shown, the first lug 46 and the second lug 48 respectively engage between the first fastening tab 52, which is fastened to the upper portion of the housing 4, and the second fastening tab 54, which is fastened to the lower portion 8 of the housing 4. The second fastening tab 54 forms a stop to prevent lateral movement of the carrier 34 by abutting against the sidewall of the frame 38, and forms a stop to prevent longitudinal movement (i.e., movement in the direction of fixing the projection lens 16) and vertical movement by forming a cylindrical sleeve with the first fastening tab 52 for receiving the first lug 48 and the second lug 48. Therefore, the fastening tabs 52 and 54 are configured such that each tilting element formed by the first lug 46 and the second lug 48 forms a pivot connection, so as to allow the carrier 34 to rotate only about the tilting axis 50.

[0075] The pivoting of the support member 34 about the tilt axis 50 allows the light-emitting unit 18 to move in the correction direction. In particular, the light-emitting unit 18 also pivots about this tilt axis. The distance between the projection lens 16 and the light-emitting unit 18, and especially the light collector 30, remains substantially the same because the tilt axis 50 is close to the projection lens 16, for example, at a distance of less than 10 mm, preferably less than 5 mm.

[0076] Figure 3 A cross-sectional view of the light-emitting module 2 is shown, illustrating the guide channel 40 defined by the baffle 36 and the light source 56 associated with the light collector 30 (mentioned above), which guides the light emitted by the light source 56 along the direction of the projection lens 16. More specifically, Figure 3 This allows it to be seen that the baffle 36 is connected to the light-emitting unit 18 on one side and is fastened to the frame 38 on the other side in a connection area specific to each baffle.

[0077] It should be noted that the following description is specific to one of the plurality of baffles 36. After necessary modifications This applies to each baffle 36. The baffle 36 is connected to the light-emitting unit 18 via an anchoring end 58 and is connected to the frame 38 in at least one engagement area. The anchoring end 58 forms the end of the baffle 36 on the opposite side of the frame 38, i.e., the end furthest from the frame 38.

[0078] More specifically, at the anchoring end 58 of the baffle 36, the baffle 36 is fitted into the light-emitting unit 18, and more specifically, into the cavity formed in the first portion 20 and the second portion 22 of the light-emitting unit 18. (See reference...) Figure 4In more detail, the anchoring end 58 has finger-like portions that can fit into complementary shaped openings formed in each of the portions 20, 22 of the light-emitting unit 18 to prevent longitudinal and lateral translational movement of the baffle 36 relative to the light-emitting unit 18, and the baffle, sandwiched between each of the portions 20, 22 forming the light-emitting unit 18, prevents vertical movement of the baffle 36 and thus the carrier 34. The finger-like portions have a circular shape, and thus the baffle 36 is pivotable relative to the light-emitting unit about a rear pivot axis 74', which is formed by the alignment of the finger-like portions arranged at the anchoring end 58 of the baffle 36. In particular, the rear pivot axis 74' of each baffle 36 is formed by the anchoring end 58 of the baffle 36.

[0079] Figure 4 and Figure 5 A more detailed view of the support member 34 is shown, particularly illustrating the connection of the baffle 36 to the frame 38 in the engagement area. Furthermore, as in... Figure 4 and Figure 5 As can be seen, the baffle 36 includes a central segment 62 extending in a main elongation plane, which in the illustrated embodiment corresponds to the nominal adjustment position and extends parallel to the longitudinal axis L and the vertical axis V. The main elongation plane of the central segment 62 is parallel to the main extension direction of the baffle 36. The central segment 62 may have a specific coating for guiding light through the guide channel 40 defined by the baffle 36.

[0080] On the opposite side of the anchoring end 58 of the baffle 36, the central segment 62 extends in a direction parallel to the main extension direction of the baffle 36 by a light-shielding segment 64 extending across the joint area. The light-shielding segment 64 extends at least one guide channel 40, such that light emitted by the light source 56 passes strictly through only one guide channel 40 from the light source 56 to the projection lens 16.

[0081] In addition, Figure 4 and Figure 5 Of particular note is that the anchoring end 58 includes finger-like portions 66 that extend vertically beyond the central section 62 to form protrusions that can be inserted into a suitable cavity in the light-emitting unit 18.

[0082] It should be noted that in the illustrated embodiment, the baffle 36 includes two finger-like portions 66 intended to fit into cavities formed in the first portion 20 or the second portion 22 of the light-emitting unit 18. Without departing from the context of the invention, the baffle 36 may include a single finger-like portion 66 intended to be inserted into a suitable cavity of the light-emitting unit 18, provided that the finger-like portion 66 participates in preventing movement of the carrier 34 relative to the light-emitting unit 18 (regarding at least the vertical and longitudinal components).

[0083] As described above, the baffle 36 is fastened to the frame 38, thereby forming at least one engagement area between the baffle and the frame, which takes the form of a resilient hinged connection. Specifically, this resilient hinged connection is achieved by locally thinning the baffle in the engagement area. More specifically, the baffle 36 is fastened to the frame 38 by a first resilient hinge connection 68 connecting the baffle 36 to the first wall 42 of the frame 38 and a second resilient hinge connection 70 connecting the baffle 36 to the second wall 44 of the frame 38.

[0084] For example, such as from Figure 1 and Figure 2 It is inferred that the carrier 34 extends between the projection lens 16 and the light-emitting unit 18, wherein the front edge 380 of the frame faces the projection lens 16 and the rear edge 382 of the frame faces the light-emitting unit 18. A first resilient hinge connection 68 connecting the baffle 36 to the first wall 42 of the frame 38 and a second resilient hinge connection 70 connecting the baffle 36 to the second wall 44 of the frame 38 are formed near the rear edge 382 of the frame 38.

[0085] The joint between the baffle 36 and the frame 38 allows the carrier 34 to form an integral assembly, wherein each baffle in the frame 38 and the baffle 36 is integrally formed. In other words, there is material continuity between the frame 38 and each baffle in the baffle 36 at the first resilient hinge connection 68 and the second resilient hinge connection 70 specific to each baffle 36.

[0086] exist Figure 4 and Figure 5 Of particular note is that each elastically deformable joint between the baffle 36 and the frame 38 does not extend the entire length of the vertical dimension of the baffle 36, but is only locally located at the joint between the first wall 42 of the frame 38 and the baffle, and at the joint between the second wall 44 of the frame 38 and the baffle 36. Therefore, the elastically deformable joint can be formed by thinning the vertical end boundary of the baffle. (As in...) Figure 4 As can be seen in particular, the baffle 36 extends vertically between the vertical upper boundary 361 and the vertical lower boundary 363, and the first elastic hinge connection 68 and the second elastic hinge connection 70 are located in the longitudinal extensions of the vertical upper boundary 361 and the vertical lower boundary 363, respectively, and are formed by reducing the thickness of the corresponding boundaries.

[0087] Figure 6 and Figure 7 An alternative embodiment of the invention is shown very schematically, which makes it easier to implement the resilient hinged connections 68, 70. Figure 6 and Figure 7In the illustrated embodiment, the support member 34 includes two baffles 36, each of which is secured to a first wall 42 of the frame 38 via a first elastic hinge connection 68 and a second wall 44 of the frame 38 via a second elastic hinge connection 70. Furthermore, the baffles 36 are in their nominal positions, i.e., in their elastically reset positions. In the illustrated embodiment, in the nominal positions of the baffles 36, the main extension direction of the baffles 36 is perpendicular to the main extension direction of the frame 34. As will be mentioned below, the nominal positions of the baffles are different in the above embodiments.

[0088] More accurately, Figure 6 An overall view of the carrier 34 according to an alternative embodiment is shown, and Figure 7 A top view of the carrier 34 according to an alternative embodiment is shown.

[0089] It should be noted that any description given in conjunction with one of the flexible hinge connections 68 or 70 After necessary modifications Applicable to another flexible hinge connection 68, 70.

[0090] The first resilient hinge connection 68 is formed using at least one gap, which is configured to form a thin region 72 of the baffle at the junction between the baffle 36 and the first wall 42. It should be understood that the second resilient hinge connection 70 is formed using at least one gap, which is configured to form another thin region 72 of the baffle at the junction between the baffle 36 and the second wall 44.

[0091] Each thin region of the flexible hinge connection forms a starting region, from which the entire baffle begins to bend when the baffle is subjected to stress at a certain distance from the thin region. In particular, when stress is applied to the baffle at the anchoring end 58 on the opposite side of the frame 38, the baffle 36 can bend from the thin region of the flexible hinge connection.

[0092] The configuration of the resilient hinge connection and the position of the first resilient hinge connection 68 relative to the second resilient hinge connection 70 mean that the baffle 36 can pivot relative to the frame 38 about the front pivot axis 74. More specifically, the front pivot axis 74 is defined by the alignment of the two resilient hinge connections 68, 70, both of which are formed near the rear end edge 382 of the wall of the frame 38.

[0093] The front pivot axis 74 of each baffle extends vertically here, perpendicular to the tilt axis 50 on the one hand and perpendicular to the main extension direction of the corresponding baffle 36 on the other hand. This tilt axis is transverse here, and the carrier 34 can be rotatably moved about this tilt axis.

[0094] It is worth noting that, for each baffle, the front pivot axis 74 formed by the alignment of the elastic hinge connections 68 and 70 and the rear pivot axis 74' formed by the alignment of the finger portion 66 at the anchoring end 58 are substantially parallel within the manufacturing tolerances.

[0095] For each of the baffles, the distance between the front pivot axis 74 and the rear pivot axis 74' is the same. When considering both baffles, the projections of the front pivot axis 74 and the rear pivot axis 74' onto directions perpendicular to these front and rear pivot axes thus form a parallelogram. Furthermore, when the light-emitting unit 18 is in the intermediate position (also known as the nominal position), i.e., when the light-emitting unit 18 has not yet moved in the adjustment direction, the baffle 36 is parallel to the optical axis 100. Therefore, the specific arrangement of the front pivot axis 74 and the rear pivot axis 74' allows the light-emitting unit to move in the adjustment direction. The adjustment direction is perpendicular to the front pivot axis 74 and the rear pivot axis 74', and substantially perpendicular to the optical axis.

[0096] More specifically, when the light-emitting unit 18 is in the nominal position, the baffle 36 is parallel to the longitudinal direction L. Therefore, the specific arrangement of the front pivot axis 74 and the rear pivot axis 74' allows the adjustment direction to coincide with the substantially lateral direction T.

[0097] Therefore, when the baffles 36 are not under stress, that is, when they are in their nominal positions, the main extension direction of the baffles 36 is inclined on the one hand relative to the direction perpendicular to the main extension direction of the frame 38, and on the other hand relative to the direction perpendicular to the front pivot axis 74.

[0098] It should be noted that when the light-emitting unit 18 moves in the adjustment direction (i.e., during lateral adjustment), the light-emitting unit as a whole does not undergo rotational movement. Only the baffle 36 can pivot. The movement induced in the light-emitting unit 18 is a circular translational movement, that is, a translation along a circular path, and the angular orientation of the light-emitting unit 18 relative to the projection lens 16 does not change during this movement.

[0099] It should also be noted that the maximum pivot angle of the baffle 36 is small enough that the circular translational movement of the light-emitting unit 18 can be approximated as a linear translational movement in the lateral direction. Therefore, the projection lens 16 will not defocus relative to the light-emitting unit 16 during the movement of the light-emitting unit in the adjustment direction. For example, the pivot angle of the baffle relative to the intermediate position (also called the nominal position) of the baffle 36 is less than 15°, preferably less than 5°, which is defined as the position when the baffle is parallel to the optical axis and, in the example shown, parallel to the longitudinal direction L.

[0100] The thickness of the thin region 72 of the baffle is measured in a dimension perpendicular to the front pivot axis 74 and perpendicular to the main extension direction of the baffle 36, and it is worth noting that, Figure 6 and Figure 7 In this region, the thickness of the baffle is reduced relative to the thickness of the baffle in the central segment 62 (e.g., in the middle between the front pivot axis 74 and the rear pivot axis 74').

[0101] At least one gap is formed in the material of one of the walls 42, 44 of the frame 38 and in the thickness of the baffle 36, creating a recess. In the illustrated embodiment, the thin region 72 is obtained through the interaction of a first gap 76 and a second gap 78 located on both sides of the baffle 36.

[0102] It should be noted that the dimensions of the resilient hinge connections 68 and 70 are determined to allow the baffle 36 to move only when sufficient external force is applied to the baffle (especially via a lateral push applied by the adjusting device). In other words, the material thickness of the baffle at the front pivot axis 74 is sufficient to prevent the baffle 36 from pivoting about its respective front pivot axis 74 under its own weight.

[0103] In particular, and as in Figure 6 As can be seen in, and even in Figure 5 As can be seen further, the resilient hinge connections 68 and 70 do not extend the entire length of the baffle, parallel to the height of the front pivot axis 74. The thickness of the baffle decreases discretely only at the joint between the baffle and each wall of the frame, at the rearward edge facing the wall. This has the advantage of allowing the baffles to retain local thickness and thus sufficient rigidity to ensure they maintain their nominal position without stress applied by the adjustment system, while providing sufficient draft angle to facilitate partial demolding at the end of the molding process.

[0104] Therefore, when the carrier 34 is positioned relative to the light-emitting unit 18, the baffles 36 remain in their nominal positions, which allows at least one of the fingers 66 of each baffle 36 to be accurately fitted into the associated cavity of the light-emitting unit 18. It should be understood that the material continuity between the baffles 36 and the frame 38 facilitates the assembly of the light-emitting module 2, and more precisely, the assembly of the carrier 34 relative to the light-emitting unit 18, because it is not necessary to independently position each of the baffles on the carrier before mounting the sub-assembly onto the light-emitting unit.

[0105] like Figure 7 As shown, each of the first gap 76 and the second gap 78 forms a continuous recess in the thickness of the baffle 36 on the one hand and in the material of the associated walls 42, 44 on the other hand, the recess having a constant radius of curvature (forming a circle 80), and the gap can be formed in particular by the presence of a cylindrical pin in the injection mold to prevent material from being injected into the region.

[0106] exist Figure 7Of particular note is that the first gap 76 and the second gap 78 have the same radius of curvature, and the two gaps are symmetrically formed on both sides of the baffle 36. This feature allows the baffle 36 to be pivoted to one side of the first gap 76 and the other side of the second gap 78 in an equally easy manner.

[0107] As already mentioned, the first gap 76 and the second gap 78 are each inscribed in a circle 80. Therefore, each of the circles 80 is centered on a straight line 82 extending perpendicular to the main extension direction of the corresponding baffle 36. The result here is that the straight line 82 centered on the circle is parallel to the main extension direction of the frame 38.

[0108] Figure 8 Showing according to Figures 1 to 5 The first gap 76 and the second gap 78 of the embodiment of the present invention are shown.

[0109] exist Figure 8 Of particular note is that, with Figure 6 and Figure 7 Unlike the illustrated embodiment, when the baffle 36 is in its nominal position, the extension direction of the baffle 36 intersects the main extension direction of the frame 38. This tilt of the frame 38 relative to the baffle 36 allows the frame 38 and the projection lens 16 to conform to the curvature of the vehicle while maintaining the longitudinal orientation of the baffle to project the light-emitting function along the optical axis 100. It should be understood that the tilt of the frame 38 relative to the baffle 36 may vary depending on the curvature of the vehicle on which the light-emitting module 2 is mounted.

[0110] Furthermore, as described above, the first gap 76 and the second gap 78 are inscribed within a circle 80 centered on a line 82. When the baffle 36 is in its nominal position, the line 82 is again perpendicular to the baffle 36, but therefore intersects the main elongation direction of the frame 38 in the illustrated embodiment. Thus, the first gap 76 extends further into the material of the frame 38 than the second gap 78.

[0111] As already mentioned, the light-emitting module 2 includes an adjustment device, which in the illustrated embodiment is formed by a lateral adjustment device and a vertical adjustment device.

[0112] The vertical adjustment device allows the light-emitting unit to move in the correction direction. Specifically, the vertical adjustment device allows the assembly formed by the carrier 34 and the light-emitting unit 18 to pivot relative to the housing 4 about the tilt axis 50 by pushing or pulling the area of ​​the light-emitting unit located longitudinally opposite the carrier 34 and the tilt axis 50. Therefore, by means of the vertical adjustment device, the user of the motor vehicle or the operator assembling the light-emitting module 2 can adjust the light emission function emitted by the light-emitting module 2.

[0113] The lateral adjustment device allows the light-emitting unit 18 to move in the adjustment direction. Specifically, the vertical adjustment device allows the light-emitting unit 18 to translate relative to the housing 4. The translational movement of the light-emitting unit 18 is a circular translational movement, i.e., a translation along a circular path. More specifically, as explained above, this circular translational movement can be approximated as a linear translation in the lateral direction. Therefore, during the lateral adjustment of the light-emitting module 2, the light-emitting unit 18 is driven to move in a substantially lateral direction (substantially parallel to axis T) by the lateral adjustment device. Due to the elastically deformable connection between each baffle and the frame of the support member 34 (the configuration of which aligns with the front pivot axis forming the baffle), the movement of the light-emitting unit 18 follows a curved path.

[0114] The method for manufacturing the carrier 34, which forms the subject of the present invention, will now be described. Particular reference will be made to… Figure 4 and Figure 8 It is worth noting that the support member 34 is obtained by a manufacturing method using a three-part mold, into which the material intended to form the frame 38 and the baffle 36 is injected. It should be understood that the frame 38 and the baffle 36 are formed of the same material (here, polyoxymethylene (also known as the acronym "POM")).

[0115] The mold forms a cavity that corresponds to the shape of the carrier 34. This cavity is created by the interaction of three parts of the mold, each part of which is designed to form a portion of the carrier 34.

[0116] More specifically, the first part of the mold participates in forming the upper section of the carrier. This first part includes, in particular, hollow portions that, when filled, form the first portion (referred to as the upper portion 360) of each baffle 36, and this first portion of the mold, together with the third part of the mold, participates in forming the upper wall 42 of the frame 38. The upper section of the carrier particularly includes the engagement area between the upper wall 42 of the frame 38 and the baffle 36, namely, an elastic hinge connection designed to be formed by the gaps arranged on both sides of the baffle in one of the elastic hinge connections 68. The upper portion 360 of each baffle 36 extends vertically between the vertical upper end boundary 361 and the middle section of the baffle, and... Figure 4 It is worth noting that the thickness of the baffle decreases as it approaches the vertical upper boundary 361, which allows for the formation of a draft angle to remove the first mold portion.

[0117] The first mold portion is removed in a first direction (here, the vertical direction) and with a movement defined by the demolding vector of the first symbol.

[0118] The second part of the mold participates in forming the lower section of the carrier. This second part specifically includes hollow portions that, when filled, form the second portion (referred to as the lower portion 362) of each baffle 36, and this second portion of the mold, together with the third part of the mold, participates in forming the lower wall 44 of the frame 38. The lower section of the carrier includes the engagement area between the lower wall 44 of the frame 38 and the baffle 36, namely another resilient hinge connection in the resilient hinge connection 70 formed by the gaps arranged on both sides of the baffle. The lower portion 362 of each baffle 36 extends vertically between the vertical lower end boundary 363 and the middle section of the baffle, and... Figure 4 It is worth noting that the thickness of the baffle decreases as it approaches the vertical lower boundary 363, which allows for the formation of a draft angle to remove the second mold portion.

[0119] The second part is removed in the first direction and with a motion defined by a demolding vector of a second symbol opposite to the first symbol.

[0120] Therefore, the third part of the mold allows for the formation of opposing walls of the frame, and in particular defines the draft angles of the inner surfaces of these walls 42, 44. The third part is removed in a second direction perpendicular to the first direction (here, in the longitudinal direction).

[0121] Therefore, the present invention does indeed achieve its stated purpose by providing a carrier that allows the light-emitting unit to be supported within the housing of the light-emitting module and guides the light emitted by the light source housed in the light-emitting unit along the direction of the fixed projection lens. This carrier facilitates the assembly of the light-emitting unit within the housing by limiting the number of operations in such a way that a plurality of baffles involved in guiding the light are integrally formed with and made of the same material as the frame of the carrier involved in supporting the light-emitting unit.

[0122] 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 feasible combinations of such devices.

Claims

1. A support (34) for supporting a light-emitting unit (18) within a housing (4) of a motor vehicle light-emitting module (2), the support (34) comprising a plurality of baffles (36) and a frame (38), the plurality of baffles being configured to define at least one channel (40) between the plurality of baffles for guiding light emitted by the light-emitting unit (18), the frame extending in a main extension direction, the baffles (36) being rotatably movable relative to the frame (38) about a front pivot axis (74) perpendicular to the main extension direction, the baffles (36) extending in a main extension direction secant from the main extension direction of the frame, the baffles including anchoring ends on opposite sides of the frame, the anchoring ends being intended to interact with the light-emitting unit, characterized in that, The baffle (36) and the frame (38) form an integral assembly, and each baffle (36) is fastened to the frame (38) by elastic hinge connections (68, 70), a first elastic hinge connection (70) is formed at the joint of the baffle (36) and the first wall (42) of the frame (38), and a second elastic hinge connection (70) is formed at the joint of the baffle (36) and the second wall (44) of the frame (38), and the front pivot axis (74) is defined by the alignment of the first elastic hinge connection (68) and the second elastic hinge connection (70).

2. The carrier as described in claim 1, wherein, Each of the resilient hinge connections (68, 70) is formed by at least one gap (76, 78), which is configured to form a thin region (72) of the baffle at the junction between the baffle (36) and one of the walls (42, 44) of the frame (38).

3. The carrier (34) as described in claim 2, wherein, The at least one gap (76, 78) forms a recess in the thickness of one of the walls (42, 44) of the frame (38).

4. The carrier (34) as described in any one of claims 2 and 3, wherein, Each of the resilient hinge connections (68, 70) is formed by a first gap (76) and a second gap (78), which are separated by a thin region (72) of the baffle.

5. The carrier as described in any one of claims 1 to 4, wherein, A baffle (36) is able to be parallel to the frame (38) about the moving front pivot axis (74) and another baffle (36) is able to be parallel to the frame (38) about at least one other moving front pivot axis (74).

6. The carrier (34) as described in any one of claims 1 to 5, wherein, When the baffle is unstressed and in its nominal position, the main extension direction of the baffle (36) is inclined relative to the direction perpendicular to the main extension direction of the frame (38) and relative to the direction perpendicular to the front pivot axis (74).

7. The carrier (34) as described in any one of claims 1 to 6, wherein, The first wall (42) of the frame (38) is the upper wall, and the second wall (44) of the frame (38) is the lower wall. The upper wall is opposite to the lower wall. The upper wall is fixed to the baffle (36) by the first elastic hinge connection (68), and the lower wall is fixed to the baffle (36) by the second elastic hinge connection (70).

8. The carrier (34) as claimed in claim 7, wherein, At least one baffle (36) includes a light-shielding section (64) extending between the lower wall of the frame and the upper wall of the frame.

9. The carrier (34) as described in any one of claims 1 to 8, wherein, Each of the plurality of baffles (36) extends parallel to the other baffles (36).

10. The carrier (34) as claimed in any one of claims 1 to 9, wherein, The frame (38) and the baffle (36) are formed of the same material. 。 11. The carrier (34) as claimed in any one of claims 1 to 10, wherein, The frame (38) includes tilting elements (46, 48) at each of the opposite lateral ends of the frame in the main extension direction of the frame, the tilting elements (46, 48) being aligned to define a tilting axis (50), and the carrier (34) being intended to be pivotally mounted in the housing of the light-emitting module about the tilting axis.

12. A motor vehicle light-emitting module (2), the motor vehicle light-emitting module comprising a carrier (34) as claimed in any one of claims 1 to 11.

13. The light-emitting module (2) as described in claim 12, comprising: - Casing (4); - Projection lens (16), which is fixed relative to the housing (4); - A light-emitting unit (18) is provided, wherein at least one light source is provided, and light emitted by the at least one light source can be projected by the projection lens (16) along the optical axis of the light-emitting module, and the light-emitting unit (18) can move relative to the projection lens (16) in an adjustment direction; - Each of the plurality of baffles (36) of the carrier (34) is connected to the light-emitting unit (18) via an anchoring end (58) of the plurality of baffles, the baffles being configured to define at least one channel for guiding light emitted by the at least one light source along the direction of the projection lens (16), and The anchoring end (58) of each of the baffles (36) is pivotally mounted relative to the light-emitting unit (18) about the rear pivot axis (74'), and Each of the baffles (36) is connected to the frame (38) of the carrier (34) by an elastic hinge connection defining the front pivot axis (74). The front pivot axis (74) and the rear pivot axis (74') are parallel to each other, and for each of the baffles (36), the distance between the front pivot axis (74) and the rear pivot axis (74') is the same. The front pivot axis (74) and the rear pivot axis (74') allow the light-emitting unit (18) to move perpendicular to the front pivot axis and the rear pivot axis and substantially perpendicular to the optical axis in the adjustment direction.

14. The light-emitting module (2) as described in claim 13, wherein, The carrier (34) supporting the light-emitting unit (18) is pivotally mounted relative to the projection lens (16) about a tilt axis (50) to allow the light-emitting unit (18) to move in a correction direction different from the adjustment direction.

15. A method for manufacturing a carrier as described in any one of claims 1 to 11, the method being carried out as follows: - At least in the first step, a cavity corresponding to the carrier is formed by juxtaposing the first, second and third portions of the mold; - At least a second step, in which material is injected into the cavity; - At least a third step, in which the first portion of the mold that participates in forming each baffle is removed in a first demolding direction with a movement defined by a demolding vector of the first symbol; - At least a fourth step, in which a second portion of the mold that participates in forming at least a second portion of each baffle is removed in the first demolding direction by a movement defined by a demolding vector of a second sign opposite to the first sign; - At least a fifth step, in which the third portion of the mold that participates in forming at least a third portion of each baffle is removed in a second demolding direction perpendicular to the first direction.

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