LIGHTING SYSTEM, HEADLIGHTS AND METHOD FOR MANUFACTURING A LIGHTING SYSTEM

Abstract

Lighting system with an optic (8) comprising at least one light guide (22) for at least one light source (6), comprising a mounting frame (10) for the optic (8) by means of which the optic (8) is attached to a circuit board (4) comprising the at least one light source (6), and comprising a spacer (15) for positioning the optic (8) which is arranged between the mounting frame (10) and the circuit board (4), wherein the spacer (15) for receiving the at least one light guide (22) has at least one continuous bearing opening (58), wherein at least one guide recess (94; 106) is provided at the edge of the at least one bearing opening (58) and at least one support surface (96) is provided at the edge on which the light guide (22) inserted into the bearing opening (58) can be supported, characterized in that on which at least one light guide (22) has a surface (80) pointing towards the spacer (15) on which the light guide (22) can be supported on the spacer (15), which at least one guide notch (94; 106) or at least part of the guide notches (94; 106) are triangular in shape, and which at least one guide recess (94; 106) or the respective guide recess (94; 106) points with its corner area away from the respective bearing opening (58) and opens / open into the respective bearing opening (58) on one side.

Description

[0001] The invention is based on a lighting system with an optical system comprising at least one light guide, wherein the optical system is arranged on a circuit board with at least one light source via a holding frame. Furthermore, the invention relates to a headlight with a lighting system and a method for producing a lighting system.

[0002] Vehicles are known from the prior art that have an Adaptive Driving Beam (ADB) as additional equipment. For example, matrix-like light-emitting diodes (LEDs) can be used for this, with the LEDs being part of a module. Each individual LED or group of LEDs in the module can then be controlled separately and thus switched on and off and dimmed. In combination with a camera system and image processing electronics, oncoming traffic and vehicles ahead, for example, are detected and at least partially blanked out. This makes it conceivable, for example, to drive permanently with "high beam" without dazzling other road users, especially under certain conditions. These conditions can include the vehicle traveling outside of built-up areas and / or traveling at a speed of over 50 km / h.In addition to other road users, obstacles such as signs can also be hidden locally.

[0003] It is necessary for the light pattern of the module with the matrix-like LEDs to be as homogeneous as possible, especially when there is no masking, for example, of other road users. At the same time, strong contrasts and steep gradients are required to separate a dark area—such as the area around a masked vehicle—from a bright area, with the bright area being as close as possible to the masked vehicle.

[0004] From DE 10 2012 220 457 A1, a lighting arrangement is known which has one or more light sources and light-guiding optics (taper) and forms the basis for the preamble of claim 1. Further relevant prior art can be found in US 2016 / 0 273 727 A1, in US 9 664 847 B2, in US 9 618 174 B2 and in DE 10 2014 104 503 A1.

[0005] The object of the present invention is to provide a lighting system and a headlight that are simple in terms of device design, cost-effective and easy to manufacture, and exhibit high light quality. Furthermore, the object of the present invention is to provide a method by which a lighting system can be manufactured in a simple and cost-effective manner.

[0006] The object is achieved with regard to the lighting system according to the features of claim 1, with regard to the headlight according to the features of claim 11 and with regard to the method according to the features of claim 12.

[0007] Particularly advantageous embodiments can be found in the dependent claims.

[0008] According to the invention, a lighting system having the features listed in claim 1 is provided.

[0009] This solution has the advantage that when the light guide is inserted from the holding frame, if it does not directly enter the bearing opening, it hits the guide recess and then slides over this into the bearing opening. This prevents the light guide from becoming jammed on the spacer during assembly. Furthermore, it is still ensured that the light guide inserted into the bearing opening can rest on the at least one support surface if necessary. The at least one guide recess thus prevents the light guide from becoming jammed on the spacer during assembly and thus not being able to be threaded into the spacer or through the spacer at all or only partially. The threading aid therefore means that no additional processes and / or tools are required to prevent or correct jamming of the light guide.This creates a lighting system that can be manufactured reliably, reliably, and with minimal fixture complexity. Even with tight joining tolerances, reliable assembly of the lighting system or light module with the taper optics and spacer is now possible. Furthermore, compression of the light guide is avoided. The at least one guide recess thus serves as a "passive threading aid" for the light guide.

[0010] By means of the lighting system according to the invention, the surface pressure between the contact surface on the light guide and the edge of the spacer opening can be partially reduced when threading the light guide at the moment of canting, which can also reduce the resistance against sliding into the spacer opening.

[0011] The at least one guide recess can be introduced on a holder side of the spacer facing away from the circuit board and towards the holding frame.

[0012] Preferably, the at least one support surface and the at least one guide recess are arranged one behind the other in the circumferential direction of the bearing opening. In other words, the at least one support surface and the at least one guide recess can be provided at the edge of the at least one bearing opening.

[0013] Preferably, the at least one guide recess, or some of the guide recesses, or all of the guide recesses are formed with a predetermined depth. Thus, the guide recess is not continuous, but rather a blind hole. In contrast, the at least one bearing opening is formed as a through-hole. Since the guide recess is not continuous, the inner wall surface of the bearing opening can be designed independently of the guide recess. In an alternative design, it is conceivable to design the at least one guide recess, or some of the guide recesses, or all of the guide recesses as continuous, which enables simpler production.

[0014] In a further embodiment of the invention, a plurality of guide recesses and / or a plurality of support surfaces are formed circumferentially around the bearing opening. Thus, during assembly, the optical fibers can impinge on the spacer at different positions and be guided into the associated bearing opening.

[0015] In a further embodiment of the invention, the optical system can comprise a plurality of optical fibers, each of which can be provided for at least one light source. These can then each have an input coupling surface and be connected on the output side via a common connecting section of the optical system. The connecting section can then have an exit surface facing away from the optical fibers. The spacer then preferably has a continuous bearing opening for each optical fiber of the optical system or at least for some of the optical fibers of the optical system.

[0016] Advantageously, at least one light guide or at least some of the light guides is provided with an entry section with the coupling surface. This is or these are, for example, circular-cylindrical or approximately circular-cylindrical in design. A light guide section can then be connected to the respective entry section or sections, which is preferably widened between the entry section and the connecting section, i.e. can represent a step in the light guide, wherein the light guide section can then widen in the direction of radiation. In this way, the light guide can be "supported" on the spacer, in particular on the at least one support surface or the plurality of support surfaces, and the distance between the light source and the light guide can be precisely adjusted and maintained.The entry section thus enables advantageous mounting, referencing, and positioning in the spacer (particularly in all three spatial directions), while allowing free shaping and directing of the light in the light guide section. In addition to cylindrical or circular-cylindrical designs, other geometries are also conceivable, such as entry sections and / or bearing openings with elliptical, rectangular, polygonal, n-gonal, or free-form cross-sections.

[0017] In a further embodiment of the invention, at least some of the guide recesses or all of the guide recesses of the at least one bearing opening are spaced apart from one another in the circumferential direction. The inner surface of the bearing opening can then be formed between two spaced-apart guide recesses, as viewed from the bearing opening, whereby the light guide can then also be supported on the bearing opening in the opening region of the guide recesses. If necessary, it is of course also conceivable for at least some of the guide recesses or all of the guide recesses to be adjacent to one another.

[0018] According to the invention, at least one guide recess or part of the guide recesses or all of the guide recesses are triangular or serrated. The serrated design enables effective threading of the optical fiber and allows sufficiently large support surfaces to be implemented. According to the invention, the triangular guide recess or a respective triangular guide recess points with its corner away from the bearing opening and opens into the bearing opening, for example, via one side, in particular all of it. The corner or corners of the triangular guide recess or a respective triangular guide recess are preferably rounded to prevent damage to the optical fiber during assembly and operation.

[0019] The guide recesses, in particular triangular ones, are arranged periodically or non-periodically, for example.

[0020] In a further embodiment of the invention, at least one guide recess, or a portion of the guide recesses, or all of the guide recesses are formed in a waveform circumferentially around the at least one bearing opening. This waveform easily avoids sharp edges to prevent damage to the optical fiber. The waveform can, for example, be periodic or non-periodic.

[0021] In a further preferred embodiment of the invention, it is conceivable that the waveform of a guide recess or of a part of the guide recesses or of all guide recesses can be described by a curve that is not differentiable in the mathematical sense. In particular, it can be provided that the waveform has edge transitions or kinks that can be described by one or more non-differentiable mathematical curve or curves. The aforementioned mathematical curve can, for example, be a one-dimensional or two-dimensional parameterizable curve that can be represented using one or two parameters. In the case of a two-dimensional parameterizable curve, the curve is designed as a surface.

[0022] Advantageously, at least one edge, or some of the edges, or all of the edges of the at least one guide recess, or of some of the guide recesses, or of all of the guide recesses between the guide recess and the holder side and / or the bearing opening, are rounded. The edge or edges are then preferably convex, so that the guide recess or guide recesses are at least partially or completely no longer sharp-edged but are instead designed with, in particular, small, curves, in order to effectively prevent the spacer, which is formed from sheet metal, for example, from cutting into the optic, which is in particular soft and made of, for example, silicone.

[0023] It can advantageously be provided that the guide recesses of at least one bearing opening or of a portion of the bearing openings engage with the guide recesses of at least one adjacent or respective adjacent bearing opening. It can thus be provided that the guide recesses of adjacent bearing openings engage with one another, but can nevertheless be spaced apart from one another. This advantageously makes it possible for the bearing openings to be arranged and formed with a small distance from one another despite the guide recesses. It is also conceivable for the guide recesses of at least one bearing opening or of a portion of the bearing openings to be spaced apart from the guide recesses of another adjacent bearing opening, in which case the adjacent guide recesses can point towards one another.In a preferred embodiment of the invention, a guide can be provided in the receiving space for at least one light guide. This allows the at least one light guide to be threaded and aligned using the existing guide geometry when the optics are inserted into the receiving space. Preferably, a guide is provided for some or all of the light guides, allowing easy insertion and alignment of the entire optics. The holding frame can therefore not only be used to protect the optics and position the optics on the circuit board, but can also comprise a threading aid for the optics. In terms of device technology, the guide or a respective guide can simply be provided as a through-hole on the bottom side of the receiving space.Furthermore, the guide or a respective guide can have a guide surface encompassing the lateral surface of the corresponding light guide, wherein preferably the guide surface or a respective guide surface is then spaced or substantially spaced from the corresponding lateral surface in the inserted state of the optics in the holding frame in order not to adversely influence the optics.

[0024] The cross-section of the guide surface or of a portion of the guide surfaces or of a respective guide surface is preferably designed with an oversize compared to the corresponding cross-section of the associated light guide(s). However, it is conceivable that one, in particular small, projection or several, in particular small, projections are provided on the guide surface or on a respective guide surface or on a portion of the guide surfaces, which projection(s) rest(s) on the light guide after assembly in order to align the corresponding light guide in a predetermined manner. The projections are, for example, point-shaped or linear or have a free form. However, the formation of the projection(s) can lead to optical losses.

[0025] Preferably, a guide or a part of the guides or all guides have a guide opening whose cross-section is designed such that the corresponding light guide hits the associated bearing opening as centrally as possible during assembly.

[0026] It is advantageous that the smallest cross-sectional area of ​​the bearing opening or of a part of the bearing openings or of a respective bearing opening is smaller than a smallest cross-sectional area of ​​the guide opening of the associated guide, and that the smallest cross-sectional area of ​​the bearing opening then lies within the smallest cross-sectional area of ​​the guide opening in the direction of the main optical axis of the respective radiation source. In other words, the guide surface or part of the guide surfaces or all of the guide surfaces in the holding frame are shaped in such a way that a maximum permissible circumferential air gap or mechanical play, considered in terms of tolerance, remains between the holding device and the corresponding light guide. This is extremely helpful in order to keep lateral offset between the light guide and the spacer as small as possible, so that the light guide can be positioned as centrally as possible on the bearing opening and, if applicable,the corresponding guide recesses. Thus, the design of the guide surfaces allows for a certain tolerance during assembly of the optics, while at least one guide recess still enables secure assembly.

[0027] Advantageously, the light guides are connected in one piece to the connecting section, which enables simple production and assembly. The optics with the connecting section and the light guides are preferably made at least partially or substantially entirely of silicone, although other transparent materials such as polymethyl methacrylate (PMMA), polycarbonate (PC), glass or optically thermoplastic materials are also conceivable, particularly depending on the distance, the specific shape of the optics and the radiation intensity / luminance of the LEDs. The light guides can project away from the connecting section and each have a lateral surface for guiding the light, thus eliminating the need for an additional cladding, as is common, for example, with light guides for data transmission. The respective lateral surface is therefore simply the interface between the material of the optics and the environment (air).The coupling surfaces of the light guides preferably extend transversely to the main optical axis of the optic. Thus, if, for example, the optic is made of silicone or liquid silicone, in combination with the precisely fitting bearing opening in the spacer, which is necessary for a tight lateral tolerance, assembly without the guide recess would not be reliably possible without additional tools due to the elasticity of the optic. Thus, the guide recesses ensure reliable assembly, especially when using optics made of a comparatively soft material.

[0028] In a preferred embodiment of the invention, a fastening element, in particular a hold-down device or a clamp, can be provided, by means of which the optic can then be easily held on the holding frame. The optic is then preferably connected to the holding frame in a force-fitting and form-fitting manner via the fastening element. In terms of device technology, the hold-down device can be designed as a clamp part that engages over the holding frame and thereby holds the optic. Such a clamp part is easy to manufacture and easy to install by simply clamping it onto the holding frame. It is conceivable for the hold-down device to have an approximately U-shaped cross-section. It can then have a base section that rests against the optic and furthermore have two legs that extend away from the base section. With the legs, the hold-down device can then engage over the holding frame, which is designed, for example, in the shape of a block.In terms of device technology, the base section of the hold-down device simply has a recess through which the optics, in particular the connecting section with the exit surface, is passed. For example, the legs of the hold-down device each have at least one recess into which a respective locking lug of the holding frame can engage to secure the hold-down device. Alternatively or additionally, the hold-down device can be provided with a locking lug on each of its legs, which can then engage in a corresponding recess in the holding frame.

[0029] The holding frame preferably has at least two locking lugs for each leg, whereby at least four locking lugs can be provided in total. Each leg can then accordingly have at least two recesses, thus enabling secure fixation of the hold-down device. The locking lug or a respective locking lug can have a ramp so that the hold-down device can be easily guided over it with its legs.

[0030] The optic is advantageously enclosed by a holding flange, particularly one that is formed as a single piece. This allows it to be easily supported on the holding frame. It is then conceivable for the receiving space of the holding frame to be designed in steps, with the light guides being arranged in a first, smaller step and the flange section being supported in the second, wider step. The hold-down device can then engage the flange surface of the holding flange that faces in the same direction as the exit surface in order to apply a holding force to the optic. This means that the light guides and the connecting section are not directly subjected to the holding force, since this force is applied to the holding flange. Furthermore, this advantageously means that the hold-down device has no negative optical influence, since it only covers the flange section and the optics are otherwise not covered by the hold-down device.

[0031] At least one contact projection can be formed on the flange surface of the optic, which preferably points in a direction away from the holding frame and thus has a certain spring effect, in particular to counteract overdefinition. The hold-down device, in particular the base section of the hold-down device, can then engage this in order to clamp the optic against the holding frame. The holding force is thus introduced via a point load on the optic via the at least one contact projection. Preferably, a plurality or multiplicity of such contact projections are provided, which are distributed, for example, circumferentially around the flange surface. The at least one contact projection or projections are, for example, frustoconical in shape, and can taper in a direction away from the optic. A different geometry and / or different arrangement of the at least one contact projection or projections is also conceivable.The contact projection(s) can be designed as point-acting springs. The hold-down device allows the optic to be connected to the mounting frame in a force- and form-fitting manner.

[0032] The holding frame preferably further comprises a centering lug that engages in a corresponding centering recess of the hold-down device to prevent incorrectly oriented or twisted installation of the hold-down device. The centering lug extends, for example, simply on the end face of the holding frame in a direction away from the circuit board and can be provided adjacent to the receiving space. The centering recess is provided, for example, on the base section and / or on one of the legs. For example, it can be introduced in the transition area from the base section to the leg. The centering lug of the holding frame and the centering recess of the hold-down device can thus be a so-called "poka-yoke" and thus a technical precaution or device to prevent errors.

[0033] The spacer can advantageously be arranged on a connecting side of the holding frame that faces away from the exit surface of the optics, i.e., is provided opposite the exit surface, and via which the holding frame can be connected to the circuit board. The spacer can advantageously be used to create a defined distance between the optics and the circuit board so that the lighting system has a light image with high efficiency and consistent quality. The spacer is preferably designed such that at least one light guide or at least some of the light guides is / are positioned precisely relative to the opposite light-emitting surfaces of the associated light sources. Furthermore, the spacer can be designed such that the holding frame and / or the optics are protected and shielded from uncoupled light, in which case the spacer can then fulfill the function of a diaphragm.This minimizes the risk that light that does not actively contribute to the light distribution will cause undesirable effects as scattered light.

[0034] Preferably, the corresponding light guide can be mounted and positioned through the continuous bearing opening, for example, transversely to the main optical axis of the optics or transversely to the main emission direction of the light sources. Preferably, the bearing opening is adapted to the corresponding light guide or to the corresponding entry section of the light guide. Thus, the lateral surface of the entry section of a respective light guide and the respective bearing opening can have a cross-section, in particular approximately the same. Thus, the surfaces can be adapted to one another in order to enable precise positioning of the light guides transversely to the emission direction of the light sources. Further preferably, it can be provided that there is play between the respective bearing opening and the corresponding light guide. Preferably, the light guide is radially spaced from the bearing opening assigned to it.

[0035] In a further embodiment of the invention, the spacer has a base section, in particular one with at least one bearing opening. A collar pointing away from the optics can then extend from this base section, via which the spacer is supported on the circuit board. The collar then maintains a defined distance from the circuit board. The circuit board's light sources can be provided opposite the base section.

[0036] At least one light guide or at least some of the light guides have a step at the transition between the entry section and the light guide section, with a step surface facing the spacer. The step surface can be annular or substantially annular and can encompass a respective light guide, although it is also conceivable for the circumferential line of a step surface to be elliptical, rectangular, trapezoidal or free-form. The respective light guide or a respective light guide is then supported on the spacer via this step surface or these. With the step surface or with the defined geometric transition surface on each individual light guide, immersion can therefore advantageously only be permitted up to a specified depth, since from a certain immersion depth of the light guide or the light guides into the corresponding bearing opening, the step surface can rest against the base plate, in particular flatly or planarly.Further immersion and the associated reduction in distance between the coupling surfaces and the emitting surfaces of the light sources is therefore not possible, thus achieving a minimum distance. Thus, a reduction in distance between the light guide and the light source due to thermal expansion of the light guides, for example, if they are made of silicone, can be prevented by the step surface being in contact with the spacer. If the light guides then, for example, lie against the spacer and further thermal expansion occurs, it is conceivable that the light guides experience a slight compression, which is then absorbed by the material of the light guides, in particular the silicone material, and the geometry. This leads to a shift of the thermally induced geometric changes to areas that are less critical from an optical point of view.In other words, direct contact of the coupling surfaces of the light guides with the light-emitting surfaces of the light sources can be avoided even in the case of large thermal expansions, thus further avoiding undefined, changing coupling effects and thus a light distribution that fluctuates over the temperature range.

[0037] The step surface preferably completely or essentially completely surrounds the associated light guide and furthermore preferably completely or essentially completely rests against the spacer - in particular above a certain temperature or within an expected temperature range - which ensures a consistent orientation of the coupling surface. If an installation within the expected temperature range is intended, it can further be provided that the step surface is installed under prestress in the expected temperature range. This has the advantage that the light guide is always in contact and is always at a defined distance from the light source. If, on the other hand, the step surface were to only rest at one point, for example, the coupling surface could be rotated with respect to that point if the optics expands thermally, which could change its orientation.This allows the angular position of the coupling surface relative to the light-emitting surface of the associated light source to remain constant, particularly parallel, which has a highly beneficial effect on the efficiency of the optics. Combined with the precise positioning perpendicular to the main emission direction of the light sources and / or perpendicular to the main optical axis, the optics can thus achieve extremely high efficiency. It can therefore be stated that the coupling surfaces of the optics can be mechanically positioned ideally and consistently relative to the light-emitting surfaces across the entire expected temperature range.

[0038] In a further embodiment of the invention, the spacer has a spring, by means of which it can be supported on the holding frame and subjected to a spring force in the direction of the circuit board. This ensures that the spacer is securely seated on the circuit board, even in the event of temperature fluctuations and the resulting geometric changes in the components of the lighting system. In terms of device technology, the spring is designed as a spring tongue on the spacer. Preferably, two, three, four or more springs or spring tongues are provided in order to provide sufficient spring force. Preferably, the springs are distributed around the spacer in order to apply the spring force evenly to it. In other words, the spring tongues formed on the spacer ensure that the contact with the circuit board surface is uniform and vibration-proof over the entire expected temperature range.

[0039] Preferably, the spacer is designed cost-effectively as a deep-drawn part. Furthermore, it is conceivable to design the support frame as a cast part, in particular as a plastic injection-molded part. The spacer can then form an insert, enabling an inlay molding process, which simplifies assembly. Alternatively, it is conceivable to design the spacer as a single piece or as a single piece with the support frame, or to combine them. In this case, a material that is sufficiently resistant to the resulting radiation intensity is preferably provided for the spacer and the support frame. Alternatively, the relevant areas of the material used can be protected by a radiation-resistant coating or metallization.

[0040] The spacer is particularly designed such that the coupling surfaces of the light guides are spaced from the light sources in the relevant or expected temperature range, in particular between -40° Celsius and +125° Celsius.

[0041] The circuit board preferably has a plurality of light sources in the form of light-emitting diodes (LEDs). An LED can be in the form of at least one individually packaged LED or in the form of at least one LED chip having one or more light-emitting diodes. Several LED chips can be mounted on a common substrate (“submount”) and form an LED, or they can be attached individually or together, for example, to a circuit board (e.g., FR4, metal-core circuit board, etc.) (“CoB” = chip on board). The at least one LED can be equipped with at least one separate and / or shared optics for beam guidance, for example, with at least one Fresnel lens or a collimator. Instead of or in addition to inorganic LEDs, for example based on AlInGaN or InGaN or AlInGaP, organic LEDs (OLEDs, e.g., polymer OLEDs) can generally also be used. The LED chips can be directly emitting or have a phosphor upstream.Alternatively, the light-emitting component can be a laser diode or a laser diode array. It is also conceivable to provide an OLED luminous layer or multiple OLED luminous layers or an OLED luminous region. The emission wavelengths of the light-emitting components can be in the ultraviolet, visible, or infrared spectral range. The light-emitting components can additionally be equipped with their own converter. The LED chips preferably emit white light in the standardized ECE white field of the automotive industry, for example, realized by a blue emitter and a yellow / green converter. The LEDs can be arranged on a surface of the circuit board facing the optics. The LEDs of the circuit board are preferably arranged in a matrix, with a respective LED being assigned to each light guide. However, it is also conceivable for multiple LEDs to be assigned to one light guide.The printed circuit board can be, for example, a metal core printed circuit board (MCPCB) or a printed circuit board with a thermally conductive core (so-called "inlay"), such as a so-called FR4 printed circuit board with a copper core or a core made of another material, or printed circuit boards made entirely of other materials, such as aluminum nitride (AlN). In addition, electronic components and parts can be provided on the printed circuit board.

[0042] In a further embodiment of the invention, it can be provided that at a certain temperature, in particular at room temperature, the stepped surfaces of the light guides rest against the spacer and the light guides are additionally subjected to a clamping force. If the temperature drops, the light guides continue to rest against the spacer. In other words, particularly when the lighting system is used in a vehicle, with an expected low subzero temperature in combination with the thermal expansion coefficient of the optics, which are made in particular of silicone, it can be provided to install the optics with a defined excess. This means in particular that at a certain temperature, in particular at room temperature, the stepped surfaces rest against the spacer with pressure.This ensures that cold-induced shrinkage of the optics does not lead to an increase in the distance between the coupling surfaces of the light guides and the light-emitting surfaces of the light sources. This shrinkage is comparatively large with silicone. Alternatively, it can be provided that at a certain temperature, particularly at room temperature, the stepped surfaces of the light guides rest against the spacer and the light guides are subjected to little or no clamping force. The magnitude of the clamping force is particularly designed such that at lower temperatures, at which the LEDs typically become brighter, the distance between the LEDs and the light guides is increased, which in turn makes the optics less efficient. As a result, these effects compensate for each other and the resulting luminous flux remains approximately constant.

[0043] In a preferred embodiment of the invention, at least one reference geometry is formed on the holding frame or on the circuit board. This reference geometry preferably extends through a reference recess, in particular a continuous one, in the spacer. Furthermore, the reference geometry can be inserted into a reference recess in the circuit board or the holding frame, depending on whether it is formed on the holding frame or on the circuit board. The reference geometry thus significantly reduces a tolerance chain. The reference geometry allows the holding frame with the optics installed therein and the spacer to be positioned and referenced with respect to the circuit board with its individual light sources. Thus, the reference geometry can be used, in particular, to position the frame transversely to the main optical axis and / or transversely to the main emission direction of the light sources, in particular in the XY plane. The optics are then simply referenced via the spacer.Preferably, the reference geometry is inserted into the circuit board or the holding frame via a plug-in assembly.

[0044] In a further embodiment of the invention, the reference geometry can preferably be designed as a reference projection, in particular a cylindrical one. Other geometries, such as triangular, square, hexagonal, polygonal, oval or free-form, are also possible. This can extend away from the holding frame, in particular parallel to the main optical axis of the optics and / or to the main emission direction of the light sources. Alternatively, the reference projection can also extend away from the circuit board. Such a reference projection is easy to manufacture. The reference recess of the spacer is, for example, designed simply as a bore in terms of device technology, which can be introduced with close tolerances. To accommodate the reference projection, the circuit board or the holding frame preferably also has a bore in terms of device technology that can be formed with close tolerances.This allows the reference geometry to penetrate the tightly toleranced holes in the spacer and the circuit board or the support frame, significantly reducing the tolerance chain. Preferably, two parallel reference projections are provided, each of which penetrates a respective reference recess in the spacer and each penetrates a respective reference recess in the circuit board or the support frame. Furthermore, the optical fibers are preferably guided through the spacer between the reference recesses.

[0045] In other words, both the circuit board and the spacer can be referenced to the same reference, namely the support frame, instead of, for example, referencing the support frame with respect to the spacer and the spacer with respect to the circuit board. Thus, the tolerance chain resulting from the individual components is minimized due to the use of reference geometries.

[0046] Since a position correction between the spacer and the holding frame, such as by lateral displacement, is prevented due to the referencing, it is particularly advantageous if at least one guide recess is provided, since this makes a position correction unnecessary.

[0047] In a further embodiment of the invention, the holding frame preferably has several contact projections, particularly at the corners, on its connection side facing the circuit board. Depending on the size and possible arrangement, only two or three contact projections can be implemented instead of four (or more). These allow the holding frame to rest against the circuit board and be further secured to the circuit board using fastening means, such as screws.

[0048] Preferably, the holding frame allows the components of the lighting system, in particular the optics, the spacer and the circuit board, to be easily fixed and precisely aligned with one another.

[0049] According to the invention, a headlight or headlight module is provided with a lighting system according to one or more of the preceding aspects. The optics are then, for example, a primary optics. Additionally, at least one secondary optics can be provided, which is arranged downstream of the primary optics.

[0050] The headlight is preferably provided in a vehicle. The vehicle can experience significant temperature fluctuations, which, thanks to the headlight according to the invention, have little or no influence on the efficiency and quality of the emitted light. The lighting system in the headlight can be used, for example, for a high beam, auxiliary high beam, or low beam, in particular for an Advanced Front Lighting System (AFS) or an Adaptive Driving Beam (ADB).

[0051] Furthermore, the headlight can be designed as a matrix headlight. This allows it to fulfill all the functions of an adaptive high beam. For example, each individual light source or group of light sources in the form of one or more LEDs in the lighting system, which can be designed as a module, can be controlled separately and thus switched on and off and dimmed. In combination with a camera system and image processing electronics and / or other sensors, oncoming traffic and vehicles ahead can be detected and partially masked out. With a sufficiently high number of pixels, it is also conceivable to separately illuminate objects detected by the camera system, such as pedestrians, animals, or obstacles, thus alerting the driver.

[0052] The vehicle can be an aircraft, a waterborne vehicle, or a land-based vehicle. The land-based vehicle can be a motor vehicle, a rail vehicle, or a bicycle. The vehicle headlight is particularly preferred for use in a truck, passenger car, or motorcycle. The vehicle can also be configured as an autonomous or semi-autonomous vehicle.

[0053] Other areas of application can include spotlights for effect lighting, entertainment lighting, architainment lighting, general lighting, medical and therapeutic lighting, horticulture, etc.

[0054] According to the invention, a method for producing a lighting system according to one or more of the preceding aspects is provided with the following steps: - Connecting and / or joining the support frame to the spacer. If necessary, additional connection to the circuit board can be provided. - Inserting or joining the optics into the holding frame and the spacer.

[0055] This solution has the advantage that at least the holding frame and the spacer can be pre-assembled, and then the optics are inserted. Thanks to the guide recesses, at least one light guide then slides securely into the corresponding bearing opening, eliminating the need for corrective access, for example, from the outside. This allows for pre-assembly of at least the holding frame and the spacer. After insertion, the optics are then preferably fixed in position to the holding frame using the fastener.

[0056] It is also conceivable that the optics are first inserted into the holding frame and then the spacer is attached.

[0057] The invention will be explained in more detail below using an exemplary embodiment. The figures show: Fig. 1 in an exploded view of an inventive lighting system according to an embodiment Fig. 2 in a perspective sectional view a holding frame with an optic of the lighting system Fig. 3 in a perspective view the holding frame with the optics and a hold-down device Fig. 4 in a perspective exploded view of the holding frame, a simplified spacer (without guide recesses and springs) and a printed circuit board Fig. 5a to 5d show parts of the lighting system in various views, in particular in the area of ​​the spacer, which is shown without guide recesses, wherein in Fig. 5c For the sake of clarity no spacer is shown Fig. 6 in a perspective view, components of the lighting system with designation of the spatial axes Fig. 7 in a cross-section a section of the spacer in the area of ​​a bearing opening with installed optics (entry section) Fig. 8a and Fig. 8b each shows a perspective view of a detailed representation of the spacer with bearing openings and exemplary design of guide recesses

[0058] According to Fig. 1 shows a headlight 1, simplified by a dashed line, comprising a lighting system 2. This has a circuit board 4 with a plurality of light sources in the form of light-emitting diodes (LEDs) 6 arranged in a matrix. The lighting system 2 also has an optic 8, which is attached to the circuit board 6 via a holding frame 10. The optic 8 is secured to the holding frame 10 via a clamp-shaped hold-down device 12. The holding frame 10 is fixed to the circuit board 4 via fastening elements in the form of screws 14. Furthermore, a spacer 15 is arranged between the circuit board and the holding frame 10 in order to precisely position the optic 8. A secondary optic (not shown) is also a component of the headlight 1 or the lighting system 2.

[0059] According to Fig. 2, the holding frame 10 has a receiving space 16 for the optics 8, facing away from the circuit board 4. The receiving space 16 has a bottom side 18 in which a plurality of through-cutouts 20 in the form of guides are formed. Light guides 22 of the optics 8 can be guided through these. The light guides 22 of the optics 8 extend from a common connecting section 24 of the optics 8 approximately parallel to the main optical axis of the optics. The connecting section 24 has an exit surface 26 on its side facing away from the light guides 22 and the holding frame 10. Each light guide 22 is assigned an LED 6, see Fig. 1, which can then couple light into the optics via the light guides 22. The light emitted by the LEDs 6 can then be brought closer together via the light guides 22. This allows dark areas between the light paths of a respective LED 6 to be avoided by overlapping the light paths at the edges through the connecting section 24.

[0060] The receiving space 16 is stepped and has a first step 28, which extends from the bottom side 18, and a widened second step 30 adjoining the first step 28. The first step 28 serves to receive the light guides 22 and the second step 30 serves to receive a holding flange 32 formed on the optics 8, which surrounds the optics 8 and is formed integrally with it. In the second step 30, a plurality of springs 34 are formed which engage in corresponding grooves 36 of the holding flange 32. This can prevent incorrectly oriented insertion of the optics 8. When the optics 8 is inserted into the holding frame 10, the holding flange 32 is then received in the second step 30 and the light guides 22 are guided through the through-cutouts 20.

[0061] According to Fig. 3 shows the hold-down device 12, by means of which the optic 8 is fixed to the block-shaped holding frame 10. The hold-down device 12, which is approximately U-shaped in cross-section, is designed as a clamp part and has a base section 37 from which extend first and second legs 38 and 40, which are arranged approximately parallel to one another. A recess 42 is formed centrally on the base section 37, through which the connecting section 24 of the optic 8 is passed. The legs 38 and 40 then overlap the block-shaped holding frame 10 laterally and each engage with two locking lugs 44, 46 formed on the holding frame 10.

[0062] Furthermore, a centering lug 48 is provided on the holding frame 10. This is flush with a side surface of the holding frame, which is overlapped by the leg 40. The centering lug 48 then extends approximately parallel to the main optical axis and projects from the rest of the holding frame 10 in a direction away from the circuit board 4, see Fig. 2. The centering lug 48 interacts with a centering recess 50 of the hold-down device 12, whereby the hold-down device 12 can only be arranged in one possible position on the holding frame 10, thus avoiding incorrect assembly.

[0063] Furthermore, according to Fig. 3, a plurality of contact projections 52 are formed on the holding flange 32. These projections are distributed circumferentially around the connecting section 24 of the optics 8. At least when the hold-down device 12 is not placed on the holding frame 10, these projections project out of the receiving space 16, see also Fig. 2. If the hold-down device 12 is then placed on the holding frame 10, the latter rests with its base section 37 against the contact projections 52 and thus applies a holding force to the holding flange 32. The optics 8 is then held between the hold-down device 12 and the second stage 30 via the holding flange 32, see also Fig. 2, firmly clamped. The holding force can advantageously be introduced into the holding flange 32 via the contact projections 52.

[0064] According to Fig. 4 shows the spacer 15 located between the holding frame 10 and the printed circuit board 4. The approximately plate-shaped spacer 15 has, on its side facing the printed circuit board 4, a collar 54 that is formed in sections around the circuit board 4. When installed, the spacer 15 rests on a plate surface 56 of the printed circuit board 4 facing the holding frame 10. Since the paint layer may be subject to considerable fluctuations in layer thickness, only the unpainted areas of the plate surface 56 provided for this purpose serve as support surfaces for the spacer 15 and the holding frame 10, due to tolerances (Z alignment). The LEDs 6 are then arranged on the printed circuit board 4. The spacer 15 then lies above the LEDs 6 and is thus arranged between them and the holding frame 10. The LEDs 6 are also arranged within the collar 54.

[0065] For a respective light guide 22, see Fig. 2, the spacer 15 has bearing openings 58, which are explained in more detail below. Furthermore, the spacer 15 has two reference recesses 60 and 62 on the sides, particularly in the form of continuous bores. These are penetrated in the assembled state by reference geometries in the form of reference projections 64 and 66 of the support frame 10. These extend according to Fig. 2 to the side of the through-holes 20 at a parallel distance to the main optical axis. According to Fig. 4, two reference recesses 68, 70 are then further provided in the circuit board 4 for the reference projections 64 and 66, into which the reference projections 64 and 66 are then immersed in the assembled state. Via the reference projections 64 and 66, the spacer 15 and the circuit board 4 are thus independently referenced and positioned relative to the holding frame 10, in particular laterally or in the X and Y directions.

[0066] According to Fig. 5a shows a perspective sectional view of a connecting side 72 of the holding frame 10, which is connected to the printed circuit board 4, see for example Fig. 1. Furthermore, the spacer 15 and the optics 8 are visible. It can be seen that the light guides 22 each have an end entry section 74 in a respective bearing opening 58, see also Fig. 4, of the spacer 15 and push it through. The spacer 15 has according to Fig. 5a spring tongues 76, wherein in the sectional view according to Fig. 5a shows two of four spring tongues 76. For the sake of simplicity, these are shown in the Fig. 4 (sectional view) is not shown. The spring tongues 76 each extend toward the support frame 10 and are supported on it. In the assembled state, they then apply a spring force to the spacer 15 in the direction of the printed circuit board 4, see Fig. 4, which ensures that the spacer 15 is placed on the circuit board 4 even at different temperatures and thus different expansions, for example of the holding frame 10.

[0067] According to Fig. 5b shows the circuit board 4, the spacer 15 and the light guides 22 in perspective and in sections. It can be seen that the end-side inlet sections 74 of the light guides 22 have a circular-cylindrical cross-section. On their side facing the LEDs 6, the inlet sections 74 then each have a coupling surface. A light guide section 78 is connected to each inlet section 74 via a step. Each light guide 22 then has, due to the step according to Fig. 5b has an annular step surface 80, wherein in the Fig. 5d shows a perspective view of a section of the spacer 15, the circuit board 4 and the light guides 22. A respective light guide 22 can extend over the step surface 80 according to Fig. 5b are supported on the spacer 15, which limits the immersion depth of the entry sections 74. This allows a minimum distance between the LEDs 6 and the coupling surfaces of the light guides 22 to be achieved. The coupling surfaces are in Fig. 5d with the reference number 82.

[0068] According to Fig. 5c is a distance in the Z-direction, i.e. in a direction parallel to the optical main axis of the optics 8 from Fig. 1, between a light-emitting surface 84 of an LED 6 and the coupling surface 82 of a light guide 22.

[0069] According to Fig. 6, the circuit board 4 and the light guides 22 are shown in a perspective view. Furthermore, the Z-direction 86, an X-direction 88, and a Y-direction 90 are shown. As already explained above, the Z-direction is the direction of the main optical axis of the optics 8 and / or a main emission direction of the LEDs 6. In the installed state of the headlight 1, see Fig. 1, in a vehicle, the Z-direction can then alternatively or additionally extend parallel to the vehicle's longitudinal axis. The X-direction 88 can then extend horizontally and the Y-direction 90 vertically. According to Fig. 6, the X-direction 88 and the Y-direction 90 are provided in a plane that extends parallel to the circuit board 4.

[0070] Fig. 7 shows a section of the spacer 15 in the area of ​​the bearing opening 58 with positioned entry section 74 of the optics 8. Here, the upper, in particular in the direction of the holding frame 10, see for example Fig. 4, facing the holder side 92 of the spacer 15. It can be seen that a plurality of serrated guide recesses 94 are formed in the edge of the bearing opening 58, of which, for the sake of simplicity, only one is provided with a reference symbol. The tips of the triangular guide recesses 94 each point approximately radially away from the bearing opening 58. Between the guide recesses 94, a plurality of support surfaces 96 are formed, of which, for the sake of simplicity, only one is provided with a reference symbol. The support surfaces 96 simply form a part or section of the approximately flat spacer surface. The guide recesses 94 and the support surfaces 96 are thus alternately formed circumferentially in the edge of the bearing opening 58. Each guide recess has, for example, two V-shaped edges 98, 100 that approach each other in the direction away from the bearing opening 58.The edges 98, 100, corner areas 104, and the bearing opening 58 are burr-free / rounded when viewed from the holder side 92 to prevent damage to the light guides 22. Furthermore, the areas 104 facing the optics in the joined state and the bearing opening 58 have no sharp edges.

[0071] The guide recesses 94 can have a different distance in the circumferential direction of the bearing opening 58. It is also conceivable to distribute these evenly over a pitch circle, as shown in Fig. 7 is shown.

[0072] According to Fig. 8a and Fig. 8b (not according to the invention) shows that guide recesses 106 have a round or curved inner surface, and can extend at least partially along a circular arc. Three guide recesses 106 are provided for each of the central bearing openings 58, while four are provided for the peripheral bearing openings. The guide recesses 106 are arranged on a pitch circle for each bearing opening 58.

[0073] The following explains the assembly of the lighting system 2. First, according to Fig. 4 the holding frame 10 is joined to the spacer 15 and the circuit board 4 and connected to each other. The joining takes place in the z-direction 86, see Fig. 6. After this, the optics 8, see for example Fig. 2, are first inserted into the holding frame 10 in the z-direction 86. The light guides 22 are inserted into the through-cuts 20 and are guided by them to the bearing openings 58 of the spacer 15, see Fig. 4. In a through-hole 20 or in a part of the through-hole 20 or in each through-hole 20, a comparatively small projection can be provided to improve the guidance of the light guides 22 during assembly. The opening cross-section of a respective through-hole 20 is selected such that a respective light guide 22 points at least onto the guide recesses 94, see Fig. 7, which is associated with the bearing opening 58. The corresponding light guide 22 can then be guided through the guide recesses 94 to the bearing opening 58 if it does not directly enter the bearing opening 58. The optics 8 of Fig. 2 can thus first be guided with its light guides 22 through the through-cutouts 20 and then the light guides 22 can be inserted into the respective bearing opening 58 and, if necessary, guided into the bearing openings 58 via the corresponding guide recesses 94. Following this, the optics 8 is then Fig. 3 is fixed by the hold-down device 12. If required, a respective light guide 22 can be moved over its step surface 80, see Fig. 5d, on the support surfaces 96 of its bearing opening 58, see Fig. 7.

[0074] Thus, it can be determined that the hold-down device 12, see Fig. 1, serves to fix the optics 8 in the holding frame 10. The optics 8 made of silicone is used for light shaping, in particular by its light guide 22, see Fig. 2. The holding frame 10, see Fig. 1 serves to position and fix all components to each other using a reference geometry and also serves as a threading aid for the optics 8. The spacer 15 is for an exact positioning of the light guides 22 relative to the light-emitting surface 84, see Fig. 5c, in the x-, y- and z-directions and for shielding the holding frame 10 from radiation.

[0075] A lighting system is disclosed with an optic having a light guide. This can be attached to a circuit board via a holding frame. A spacer can be arranged between the optic and the circuit board in order to position the at least one light guide precisely relative to a light source provided on the circuit board. The plate-shaped spacer has a bearing opening for positioning the light guide, into which the light guide is inserted. The bearing opening has at least one guide recess on its edge region and at least one support surface facing the holding frame. During assembly, the light guide can then be guided via the guide recess towards the bearing opening if it encounters the edge region of the bearing opening. The light guide can then support itself via its lateral surface via the support surface if necessary. LIST OF REFERENCE SYMBOLS 1 headlight 2 Lighting system 4 circuit board 6 LED 8 Optics 10 holding frames 12 hold-down clamps 14 screws 15 spacers 16 Recording room 18 Bottom side 20 through recess 22 light guides 24 connecting section 26 Exit surface 28, 30 level 32 retaining flange 34 spring 36 grooves 37 Base section 38 legs 40 legs 42 recess 44, 46 locking lug 48 Centering nose 50 hold-down clamps 52 investment advantages 54 collar 56 plate area 58 Warehouse opening 60, 62, 68, 70 reference recess 64, 66 Reference lead 72 Connection side 74 Entry section 76 spring tongue 78 fiber optic section 80 step area 82 coupling area 84 light-emitting surface 86 z-direction 88 x-direction 90 y-direction 92 holder side 94; 106 guide recess 96 support surface 98, 100 edge 104 Corner area

Claims

[1] A lighting system comprising an optical system (8) having at least one light guide (22) provided for at least one light source (6), comprising a holding frame (10) for the optical system (8), by means of which the optical system (8) is fastened to a circuit board (4) having the at least one light source (6), and comprising a spacer (15) for positioning the optical system (8), which is arranged between the holding frame (10) and the circuit board (4), wherein the spacer (15) has at least one continuous bearing opening (58) for receiving the at least one light guide (22), wherein at least one guide recess (94; 106) is provided at the edge of the at least one bearing opening (58), and at least one support surface (96) is provided on the edge, on which the light guide (22) inserted into the bearing opening (58) can be supported, characterized by , that on the at least one light guide (22) a surface (80) facing the spacer (15) is formed, via which surface the light guide (22) can be supported on the spacer (15), at least one guide recess (94; 106) or at least a part of the guide recesses (94; 106) are triangular, and the at least one guide recess (94; 106) or the respective guide recess (94; 106) points / points with its corner region away from the respective bearing opening (58) and opens / opens via one side into the respective bearing opening (58). [2] Lighting system according to claim 1, wherein a plurality of guide recesses (94; 106) and / or support surfaces (96) are formed circumferentially around the respective bearing opening (58). [3] Lighting system according to claim 1 or 2, wherein the optics (8) has a plurality of light guides (22), each provided for at least one light source (6) and each having a coupling surface (82), and wherein the light guides (22) are connected on the output side via a common connecting section (24) of the optics (8), which has an exit surface (26) pointing away from the light guides (22). [4] Lighting system according to claim 2 or 3, wherein at least some of the guide recesses (94; 106) are spaced apart from one another in the circumferential direction. [5] Lighting system according to one of the preceding claims, wherein at least one guide recess (94; 106) or at least a part of the guide recesses (94; 106) is / are formed circumferentially around the respective bearing opening (58). [6] Lighting system according to claim 5, wherein a part of the plurality of guide recesses (94; 106) is wave-shaped, and wherein the waveform can preferably be described in the mathematical sense by one or more non-differentiable curve or curves. [7] Lighting system according to one of claims 2 to 6, wherein some or all of the guide recesses (94) are arranged periodically or non-periodically. [8] Lighting system according to one of the preceding claims, wherein at least one edge (58, 98, 100, 104) of the at least one guide recess (94) or at least a part of the guide recesses (94) is rounded. [9] Lighting system according to one of claims 2 to 8, wherein the guide recesses (94) of at least one bearing opening (58) engage in the guide recesses (94) of at least one adjacent bearing opening (58), and / or wherein the guide recesses (94) of at least one bearing opening (58) are spaced from the guide recesses (94) of a further adjacent bearing opening (58), wherein the adjacent guide recesses (94) of the adjacent bearing openings (58) face one another. [10] Lighting system according to one of the preceding claims, wherein, viewed in the direction of the longitudinal axis of the at least one bearing opening (58), the bearing opening (58) lies within an associated guide opening (20) of the holding frame (10). [11] Headlight with a lighting system according to one of the preceding claims. [12] A method for manufacturing a lighting system according to any one of claims 1 to 10, comprising the steps of: - Connecting the holding frame (10) to the spacer (15), - Insert the optics (8) into the holding frame (10) and the spacer (15).

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