Light module with improved positioning of an optical unit relative to a light source

Abstract

Light module arranged in a housing of a vehicle headlight, comprising a heat sink (10) on which a circuit board (11) is mounted, wherein at least one light source (12) is mounted on the circuit board (11) and can be cooled via the heat sink (10), and comprising an optical unit (13) which is attached to the heat sink (10) and arranged in front of the circuit board (11) such that light generated by the at least one light source (12) can be directed into the optical unit (13), wherein the optical unit (13) has positioning means (14) which are operatively connected with counter-positioning means (15) of the circuit board (11), thereby generating a positioning of the optical unit (13) relative to the at least one light source (12), characterized in that the optical unit (13) has a lens holder (19) and a lens (20), wherein the positioning means (14) are arranged on the lens holder (19).wherein the optical unit (13) is attached to the heat sink (10) only by means of screw elements (18).

Description

[0001] The present invention relates to a light module for arrangement in a housing of a headlight, with a heat sink on which a circuit board is mounted, wherein at least one light source is mounted on the circuit board which can be cooled via the heat sink and with an optical unit which is attached to the heat sink and is arranged in front of the circuit board in such a way that light generated by the light source can be directed into the optical unit. STATE OF THE ART

[0002] US Patent 2013 / 0 250 599 A1 describes a light module for installation in a headlight housing. The light module has a heat sink as its base, and a circuit board is mounted on the heat sink, on which a light source is mounted. The light source can be cooled via the heat sink. Furthermore, an optical unit is provided, which is attached to and positioned on the heat sink. This ensures precise positioning of the optical unit above the light source. However, this requires precise mounting geometries on the heat sink for both the circuit board and the optical unit. In addition to the required precise mounting geometries on the heat sink, a tolerance chain develops between the circuit board with the light source and the optical unit. The accumulation of these tolerances can lead to deviations in the intended position of the light source relative to the optical unit.The optical unit can, for example, consist of a lens holder and a lens, and it is often necessary to position the light source as precisely as possible relative to the lens to achieve optimal lighting performance. Such light modules can, for example, function as signal lights, high beams, or low beams for a vehicle's headlights. Particularly in light modules that generate low beams, very precise positioning of the light source relative to the lens is required. The light source can preferably be a semiconductor light source, and it can be a single light source or comprise several individual light sources. REVELATION OF THE INVENTION

[0003] The object of the invention is to improve the positioning of an optical unit relative to a light source in a vehicle lighting module. The lighting module is intended, in particular, for installation in the housing of a vehicle headlight. The lighting module should have components that are as easy to manufacture as possible, and in particular, the lighting module should be easy to assemble.

[0004] This problem is solved by means of a light module for arrangement in a housing of a headlight for a vehicle according to the preamble of claim 1 in conjunction with the characterizing features. Advantageous embodiments of the invention are specified in the dependent claims.

[0005] The invention includes the technical teaching that the optical unit has positioning means which are in operative contact with counter-positioning means of the circuit board, thereby generating a positioning of the optical unit to the light source.

[0006] The invention advantageously utilizes the possibility of creating a positioning mechanism between the circuit board and the optical unit, with the optical unit simultaneously being attached to the heat sink. The attachment of the optical unit to the heat sink can be designed such that the positioning between the optical unit and the circuit board allows for precise alignment of the optical unit in front of the light source, while the optical unit is conventionally held in place on the heat sink. The circuit board with the light source can also be mounted on the heat sink to enable heat dissipation from the light source in a known manner.

[0007] The simple creation of the functional connection between the positioning means of the optical unit and the counter-positioning means of the circuit board allows the optical unit to be positioned precisely above the light source, while the optical unit can be attached to the heat sink in a conventional manner.

[0008] According to an advantageous embodiment, the heat sink can have positioning means that interact with counter-positioning means on the printed circuit board (PCB), thereby positioning the PCB on the heat sink. The PCB can also include further counter-positioning means that interact with positioning means on the heat sink, enabling precise alignment of the PCB on the heat sink. Alternatively, the PCB can be attached to the heat sink in a conventional manner, for example, using screws. Precise positioning of the PCB on the heat sink can also be provided without affecting the arrangement of the optical unit in front of the light source on the PCB. For example, the optical unit can be attached to the heat sink using screws.The screw elements can remain slightly movable in the provided through-holes, allowing the operative connection between the positioning elements on the optical unit and the counter-positioning elements on the circuit board to be established first. The optical unit is then secured to the heat sink using the screw elements. While the optical unit is being fastened to the heat sink via the screw elements, its position above the circuit board remains unchanged; it is simply attached to the heat sink. The counter-positioning elements can provide a kind of guidance for the positioning elements, enabling precise positioning of the optical unit above the light source despite the use of simple screw elements.

[0009] According to an advantageous embodiment of the light module according to the invention, the positioning means on the optical unit can be formed by positioning domes, while the counter-positioning means on the circuit board can be formed, for example, by catch holes. This allows the optical unit to be positioned in front of the circuit board by having the positioning domes engage in the catch holes. Similarly, the catch holes can also be provided on the optical unit, and the positioning domes can be attached to the circuit board to engage in the catch holes in the same way.

[0010] Positioning elements on the heat sink can also be formed by positioning domes, while the corresponding positioning elements on the circuit board can be formed by catch holes. Similarly, when the circuit board is mounted on the heat sink, the positioning domes can be seated in the catch holes.

[0011] The optical unit can comprise a lens holder and a lens, with the positioning means preferably arranged on the lens holder. Similarly, the optical unit can also comprise a reflector holder and a reflector. The lens holder can be formed from a plastic injection-molded component, with the positioning domes forming the positioning means being integrally molded onto the lens holder, for example, by injection molding.

[0012] The heat sink can be formed from an aluminium die-cast component, whereby the positioning domes forming the positioning means can be integrally molded onto the heat sink.

[0013] The light module can be designed to be mounted in a support frame. The light module can be attached to the support frame above the heat sink. This offers the advantage that the heat sink, which has a large mass, is attached directly to the support frame, while the optical unit is attached to the heat sink and can be moved together with it as a single unit. According to an advantageous further development, positioning means can also be provided on the support frame, which can be operatively connected to counter-positioning means on the optical unit. PREFERRED EXAMPLE OF THE INVENTION

[0014] Further measures improving the invention are described in more detail below, together with a description of a preferred embodiment of the invention, with reference to the figures. The figures show:

[0015] Fig. 1 A perspective, unassembled arrangement of a light module with a heat sink, a circuit board and an optical unit,

[0016] Fig. 2 a mounting view of the light module with an optical unit before it is mounted on the heat sink and

[0017] Fig. 3 A perspective view of a light module with a heat sink and an optical unit, shown in a mounting position in front of a support frame.

[0018] Fig. Figure 1 shows the components of a light module according to the invention in a flying view. The light module includes a heat sink. 10 for example, an aluminum die-cast component. The heat sink has a front surface. 10 a mounting surface 24 on and on the mounting surface 24 will be in front of the heat sink 10 shown circuit board 11 Assembled. Positioning of the circuit board 11on the mounting surface 24 This is achieved by positioning means arranged on the heat sink. 16 in the form of positioning domes. The positioning domes protrude from the mounting surface. 24 out and can be used when placing the circuit board 11 in counter-positioning means 17 Intervene, which are designed as catch holes. This ensures that the circuit board 11 First, determine the exact position on the mounting surface. 24 of the heat sink 10 occupies. For mounting the circuit board 10 Screw elements not shown can be used, which pass through through holes. 25 in the circuit board 11 through and into screw holes 26 in the heat sink 10 screwed in (screw elements) 27 , see Fig. 2).

[0019] Furthermore, the light module has an optical unit 13on, which consists of a one-piece lens holder made from a plastic component 19 and a lens 20 is constructed. At the optical unit 13 are positioning devices 14 in the form of positioning domes that are integrated as a single unit with the lens holder 19 are executed. The optical unit will be 13 on the heat sink 10 arranged so that the positioning means can 14 in counter-positioning means 15 intervene, which act as trap holes in the circuit board 11 are inserted. So that the positioning domes on the lens holder 19 not on the mounting surface 24 to place, the mounting surface 24 Immersion bores 28 on, which extend freely into the positioning means 14 allow. The counter-positioning devices designed as catch holes. 15 in the circuit board 11can be designed as circular openings or, as the exemplary embodiment shows, a counter-positioning means can be used. 15 as a round trap hole (right side) and another counter-positioning device 15 It can be designed as an elongated trap hole (left side). This prevents the positioning domes from binding to the optical unit. 13 in the trap holes on the circuit board 11 can be avoided. Similarly, the counter-positioning devices can be used. 17 one as a round hole and one as an elongated hole in the circuit board 11 be trained.

[0020] In front of the lens holder 19 is an aperture 29 shown above the one on the heat sink 10 arranged circuit board 11 can be arranged, whereby the aperture 29 an aperture 30 exhibits which are related to the position of the light source 12is brought into harmony so that the light source 12 light generated through the aperture 30 can pass through it. Through the aperture 29 are particularly on the circuit board 11 The recorded electronic components are protected from sunlight, which under unfavorable circumstances can pass through the lens. 20 enter from the outside of the light module and onto the circuit board 11 can focus.

[0021] Fig. 2 shows the light module with the circuit board 11 in arrangement on the heat sink 10 , whereby the mounting of the circuit board 11 with the screw elements 27 is shown. After the aperture is positioned. 29 inside the lens holder 19 can the optical unit 13 together with the aperture 29 (see here) Fig. 1) on the receiving side of the heat sink 10be arranged. The positioning of the optical unit 13 in front of the heat sink 10 shows the mounting position from which the optical unit 13 in the direction of the arrow shown, towards the front of the heat sink 10 is moved. The positioning devices are then brought into contact with the surface. 14 (see here) Fig. 1) into the counter-positioning means 15 , so that the optical unit 13 relative to the circuit board 10 is positioned precisely. Then, the screw elements shown can be used. 18 the optical unit 13 with the heat sink 10 They will be screwed together.

[0022] Fig. Figure 3 shows the light module in an assembled arrangement and the optical unit 13 with the lens holder 19 and the lens 20 is on the front of the heat sink 10It is positioned and screwed in place. The light module, which thus forms a structural unit, can be attached to a support frame. 21 to be mounted, and via the support frame 21 The light module can preferably be movably mounted within the housing of a headlight. For attaching the light module to the support frame... 21 These are, in turn, positioning devices 22 on the support frame 21 The positioning domes are designed as such (a front positioning dome is visible due to perspective, a rear positioning dome is concealed). 22 on the support frame 21 can be used in counter-positioning devices 23 at the optical unit 13 intervene, whereby the counter-positioning means 23 as catch holes in the lens holder 19 the optical unit 13 are executed.

[0023] Will the optical unit 13 to the support frame 21brought into position, the positioning devices are then brought into view. 22 in combination with the counter-positioning devices 23 and then screw elements can be used 31 the light module on the support frame 21 They will be screwed together.

[0024] By the positioning of the optical unit according to the invention 13 to the circuit board 11 and the simultaneous holding arrangement of the optical unit 13 on the heat sink 10 The advantage of very precise illumination with the light source is... 12 generated light into the lens 20 This results in high light quality from the light module. In particular, costly modifications to the heat sink are eliminated. 10 , since it is no longer within the tolerance chain between the lens 20 and the light source 12 is arranged. The lens 20 can be achieved using additional positioning aids on the lens holder 19can be positioned, in particular a plastic welding process can be used to attach the lens. 20 made of a plastic material on the lens holder 19 This process also involves the fabrication of a plastic material. One welding method could be, for example, a laser transmission process.

[0025] The invention is not limited in its implementation to the preferred embodiment described above. Rather, a number of variants are conceivable, which utilize the solution presented even in fundamentally different designs. All features and / or advantages arising from the claims, the description, or the drawings, including design details, spatial arrangements, and process steps, can be essential to the invention, both individually and in various combinations. Reference symbol list 10 heat sinks 11 Circuit board 12 light bulbs 13 optical unit 14 Positioning devices 15 Counter-positioning devices 16 positioning devices 17 Counterpositioning devices 18 screw element 19 lens holders 20 lenses 21 support frames 22 Positioning devices 23 Counter-positioning devices 24 mounting surface 25 through hole 26 insertion holes 27 Screw element 28 Immersion bore 29 aperture 30 aperture 31 Screw element QUOTES INCLUDED IN THE DESCRIPTION

[0026] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0027] US 2013 / 0250599 A1

[0002]

Claims

[1] Light module for arrangement in a housing of a headlight, with a heat sink ( 10 ), on which a circuit board ( 11 ) is recorded, with the circuit board ( 11 ) at least one light source ( 12 ) is recorded, which is via the heat sink ( 10 ) is heatable, and with an optical unit ( 13 ), which are attached to the heat sink ( 10 ) is attached and thus in front of the circuit board ( 11 ) is arranged so that the light source ( 12 ) generated light into the optical unit ( 13 ) can be irradiated, characterized by that the optical unit ( 13 ) Positioning device ( 14 ) exhibits which are equipped with counter-positioning means ( 15 ) the circuit board ( 11 ) are in active interaction, thereby enabling the positioning of the optical unit ( 13 ) to the light source ( 12 ) is generated. [2] Light module according to claim 1, characterized bythat the heat sink ( 10 ) Positioning device ( 16 ) exhibits which are equipped with counter-positioning means ( 17 ) the circuit board ( 11 ) are in active connection, which allows for positioning of the circuit board ( 11 ) on the heat sink ( 10 ) is generated. [3] Light module according to claim 1 or 2, characterized by that the optical unit ( 13 ) on the heat sink ( 10 ) by means of screw elements ( 18 ) is attached. [4] Light module according to any one of claims 1 to 3, characterized by that the positioning means ( 14 ) at the optical unit ( 13 ) are formed by positioning domes, and wherein the counter-positioning means ( 15 ) on the circuit board ( 11 ) are formed by trap holes, so that when the optical unit is arranged ( 13 ) in front of the circuit board ( 11 ) the positioning domes are seated in the trap holes. [5] Light module according to one of the preceding claims, characterized by that the positioning means ( 16 ) on the heat sink ( 10 ) are formed by positioning domes, and wherein the counter-positioning means ( 17 ) on the circuit board ( 11 ) are formed by trap holes, so that when the circuit board is arranged ( 11 ) on the heat sink ( 10 ) the positioning domes are seated in the trap holes. [6] Light module according to one of the preceding claims, characterized by that the optical unit ( 13 ) a lens holder ( 19 ) and a lens ( 20 ) has, wherein the positioning means ( 14 ) on the lens holder ( 19 are arranged. [7] Light module according to claim 6, characterized by that the lens holder ( 19 ) is formed from a plastic injection-molded component, wherein the positioning means ( 14 ) forming positioning domes one-piece on the lens holder ( 19are molded. [8] Light module according to any of the preceding claims, characterized by that the heat sink ( 10 ) is formed by an aluminum die-cast component, wherein the positioning means ( 16 ) forming positioning domes as a single unit on the heat sink ( 10 are molded. [9] Light module according to any of the preceding claims, characterized by that the light module is designed for mounting in a support frame ( 21 ) is designed, wherein the attachment of the light module to the support frame ( 21 ) via the heat sink ( 10 ) is formed. [10] Light module Claim 9, characterized by that on the support frame ( 21 ) Positioning device ( 22 ) are provided, which are equipped with counter-positioning devices ( 23 ) at the optical unit ( 13 ) can be brought into a therapeutic relationship.

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