LIGHT, VEHICLE AND METHOD FOR MAKING A LIGHT

Abstract

Lamp (50) for a vehicle with at least one reflector (1) and at least one light module (26), wherein the at least one reflector (1) has at least one reflective surface (2) on which light from the at least one light module (26) can be reflected, and at least one positioning surface (23) on which the at least one light module (26) can be positioned on the at least one reflector (1) in at least one plane, wherein the at least one reflective surface (2) and the at least one positioning surface (23) are designed and arranged such that they can be manufactured in a common, integrally formed mold half (20) of a tool, wherein light emitted by the at least one light module (26) can be reflected by the at least one reflector (1) and the at least one light module (26) is attached to the at least one reflector (1).wherein the at least one reflector (1) has the at least one positioning surface (23) and the at least one light module (26) has at least one further positioning surface (46, 48), wherein the positioning surfaces (23, 46, 48) of the at least one light module (26) and of the at least one reflector (1) cooperate to position the at least one light module (26) relative to the at least one reflector (1) and the at least one light module (26) is positioned relative to the at least one reflector (1) via the positioning surfaces (23, 46, 48) of the at least one light module (26) and of the at least one reflector (1) in the at least one plane, characterized in that the at least one light module (26) has a heat sink (32) and a circuit board (28) and at least one light source (30) which is electrically contactable with the circuit board (28), wherein the heat sink (32) has the at least one positioning surface (46,48) of which has at least one light module (26).

Description

[0001] The invention relates to a reflector for a lamp. Furthermore, the invention relates to a lamp for a vehicle, a tool for producing the reflector, and a vehicle. Additionally, the invention relates to a method for manufacturing the lamp.

[0002] Vehicles typically use a headlight system to illuminate the road, producing low or high beams. This system includes a reflector that reflects light from a light source, such as an LED, LED assembly, or LED array (LED = light-emitting diode). Precise positioning of the light source relative to the reflector is crucial, as the reflector's light-gathering efficiency, and therefore the beam pattern and overall light output of the headlight system, depend on this accuracy. If precise positioning cannot be guaranteed, the reflector's size must be increased to achieve the desired light output.Furthermore, for design reasons, a smaller reflector may be desired, but at the same time, legal requirements must be met to ensure legally mandated road illumination. Precise positioning is also necessary here.

[0003] To ensure accurate positioning of the reflector relative to the light source, the light source is currently shifted relative to the reflector during assembly until the desired light output is achieved (lateral adjustment). This is done with the light source switched on to capture and measure the light pattern emitted by the reflector. Depending on the light pattern, the light source is then shifted relative to the reflector as needed to obtain the desired light pattern. Afterward, the light source, which is contained, for example, in a light module, is mechanically fixed relative to the reflector. This positioning process is very complex and results in comparatively high manufacturing costs.

[0004] Another way to position the reflector relative to the light source is to incorporate two pins on the reflector for positioning the light source, which is integrated into a light module. These pins engage in recesses within the light module, which contains the light source, to position the module relative to the reflector. The pins are conventionally designed so that, during the injection molding process, they are formed perpendicular to the demolding direction of a reflective surface or facets where light from the light source is reflected. The reflector is designed in such a way that the negative impact on the resulting light distribution remains acceptable. For example, the focal length of the reflector is increased. Furthermore, to ensure the reflector's collection efficiency, it can be made larger.This possibility also increases the manufacturing costs of the reflector. Furthermore, the fact that the reflector must be made larger to ensure sufficient light output despite imprecise positioning can have additional disadvantages in the design of the headlight system.

[0005] One object of the present invention is to provide a technically simple and cost-effective reflector for a lamp, on which a light module can be positioned easily and with sufficient accuracy. A further object of the present invention is to provide a technically simple and cost-effective lamp for a vehicle, comprising the reflector and a light module, wherein the light module can be positioned easily and with sufficient accuracy on the reflector. A further object of the invention is to provide a technically simple and cost-effective tool for manufacturing the reflector and a technically simple and cost-effective vehicle with the reflector. Additionally, it is a further object of the invention to provide a simple and cost-effective method for manufacturing the lamp.

[0006] The problem with regard to the reflector is solved according to the features of claim 1. The problem with regard to the lamp is solved according to the features of claim 4. Furthermore, the problem with regard to the tool is solved according to the features of claim 13, and the problem with regard to the vehicle is solved according to the features of claim 14. The problem with regard to the method is solved according to the features of claim 15.

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

[0008] According to the invention, a reflector for a light, in particular for a vehicle light, is provided, wherein the reflector has at least one reflective surface. Light from a light module, in particular an LED (light-emitting diode) module, can be reflected off this surface. Furthermore, the reflector has at least one positioning surface, or two positioning surfaces, or more than two positioning surfaces, by means of which the light module can be positioned on the reflector in a plane or at least in one direction. The reflective surface and the positioning surface are designed and arranged such that they can be manufactured in a single, integrally formed mold half of an injection mold. That is, the reflector can, for example, be manufactured with a mold consisting of at least two mold halves.The reflective surface and the positioning surface are designed such that they can be produced by one of the mold halves in a form-fitting and / or form-bound manner. This means that the mold half through which the reflective surface and the positioning surface can be produced is uninterrupted and is not a movable tool element, such as a slide.

[0009] Because the reflective surface and the positioning surface can be manufactured in a single tool, they are precisely and unambiguously positioned relative to each other during production. In other words, the reflective surface and the positioning surface are directly linked to the mold. This allows for a shorter tolerance chain compared to conventional reflector manufacturing. For example, in conventional reflector manufacturing, it was necessary to position one mold half containing the reflective surface relative to another mold half containing the positioning surface before production. This is unnecessary with the reflector where the positioning surface and the reflective surface are manufactured in a single tool. Therefore, due to the shortened tolerance chain, this reflector is more cost-effective compared to a conventional reflector.Furthermore, the reflector can be positioned with sufficient precision relative to the light module due to the shortened tolerance chain. Therefore, the reflector can be smaller compared to a conventional reflector, as the sufficiently precise positioning results in high reflector collection efficiency, thus achieving adequate light output even with a smaller reflector. Another advantage is that the light module can be positioned quickly and accurately on the reflector using the positioning surface. Positioning does not require, for example, relative displacement of the light source to the reflector, as is the case with a conventional reflector. Additionally, the precise positioning of the light module relative to the reflector allows for higher quality light distribution, as the light distribution depends on the positioning of the light module relative to the reflector.

[0010] In particular, the reflective surface and the positioning surface are designed such that they can be demolded in a common direction. This means that, after being manufactured in the same mold half, the positioning surface and the reflective surface can be removed from the mold half in the same direction. This simplifies the manufacturing process of the reflector. Additionally, this simplifies the design of the reflector.

[0011] In particular, the reflector can be produced by injection molding (thermoplastic) or injection compression molding (thermoset). This is a suitable method for manufacturing the reflector quickly and cost-effectively.

[0012] According to the invention, a lamp for a vehicle is provided, comprising at least a reflector. The lamp additionally includes a light module, in particular an LED module, wherein the light emitted by the light module is reflectable by the reflector. Like the reflector, the light module also has at least one positioning surface, or two positioning surfaces, or more than two positioning surfaces. The positioning surfaces of the reflector and the light module cooperate to position the light module relative to the reflector. In other words, preferably, a positioning surface of the reflector and a positioning surface of the light module each form a surface pair. In particular, the light module can be positioned relative to the reflector in two spatial directions via the positioning surfaces. Specifically, the two spatial directions can be perpendicular to each other. The cooperating positioning surfaces simplify the mounting of the lamp.This reduces the manufacturing costs of the luminaire. Furthermore, the reflector, whose reflective and positioning surfaces can be produced in a single mold half, allows for sufficiently precise positioning of the reflector relative to the light module. This reliably ensures adequate light output from the luminaire.

[0013] The positioning surfaces of the light module and the reflector are preferably designed such that the light module can be positioned relative to the reflector in the plane, which in particular contains the two spatial directions, via three contact points to achieve three-point referencing. In other words, the positioning surfaces serve as a reference for positioning the reflector and the light module relative to each other. Overall, the positioning surfaces can be aligned in a three-line arrangement. The contact lines can form the edges of a triangular virtual prism, thus creating three-point prism referencing. The three contact points where the positioning surfaces meet allow the reflector and the light module to be precisely positioned relative to each other in the plane. This is advantageous because it prevents over-positioning of the reflector and the light module.Therefore, positioning is sufficiently precise and quick. This makes the light fixture particularly cost-effective to manufacture and assemble.

[0014] In particular, the light module can be positioned relative to the reflector in three spatial directions, with the first and second spatial directions each being perpendicular to the third spatial direction and perpendicular to each other. In other words, all three spatial directions are perpendicular to one another. The plane in which the light module can be positioned relative to the reflector via the positioning surfaces includes, in particular, the first and second spatial directions. If the light is mounted on a vehicle, the first spatial direction can be a longitudinal direction of the vehicle. The second spatial direction can be a transverse direction of the vehicle, and the third spatial direction can be a vertical direction or upward direction of the vehicle.

[0015] The positioning surfaces of the reflector and the light module are designed such that they abut each other tangentially at the contact points when viewed in the plane. Specifically, the positioning surfaces abut each other along three contact lines, which extend in the third spatial direction, particularly the vertical direction of the vehicle. Because the positioning surfaces abut each other tangentially at the contact points in the plane, which includes the first and second spatial directions, it is ensured that the reflector and the light module are not misaligned relative to each other. In other words, this method provides a simple and cost-effective way to ensure that the positioning surfaces abut each other at the contact points when viewed in the plane, and not, as with conventional luminaires, over a larger area.

[0016] It is advantageous if one of the positioning surfaces of the reflector or the light module is arc-shaped or semicircular in the plane containing the first and second spatial directions in the area of ​​the contact points. The positioning surface cooperating with this positioning surface preferably extends along a straight line in the plane containing the first and second spatial directions, at least in the area of ​​the contact points.

[0017] In other words, the positioning surface of the reflector or light module has an arc-shaped cross-section perpendicular to the third spatial direction. Along the third spatial direction, it is conceivable that the positioning surface has a constant cross-section. The opposite positioning surface of the other component, i.e., the light module or reflector, is then preferably flat or substantially flat and extends, for example, along the third spatial direction. Thus, point contact between the opposite positioning surfaces can be achieved in the plane spanned by the first and second spatial directions. It is also conceivable to design the positioning surface to be curved in such a way that line contact, particularly along the third spatial direction, exists between the positioning surfaces—that is, between the curved and the flat positioning surface.It would also be conceivable to design both interacting positioning surfaces with an arc-shaped cross-section to achieve point or line contact. The two interacting positioning surfaces of the reflector and the light module preferably form a pair of surfaces. More preferably, a pair of surfaces is formed from a curved and a flat positioning surface. The described design is advantageous because the positioning surfaces thus lie tangentially at the contact points.

[0018] In a further embodiment of the invention, at least two or at least three pairs of surfaces are provided between the reflector and the light module. It is conceivable that one component, for example the reflector, has the flat positioning surfaces, and the other component, for example the light module, has the curved positioning surfaces. A mixture of curved and flat positioning surfaces on one component is also conceivable, with the other component then naturally also having a corresponding mixture. Preferably, two positioning surfaces of one of the components are arranged in a V-shape relative to each other and form a V-shaped receiving space in which two opposing positioning surfaces of the other component are arranged. Furthermore, it is possible that a third positioning surface is spaced apart from the V-shaped positioning surfaces on the same component.The third positioning surface is preferably oriented differently compared to the V-shaped positioning surfaces.

[0019] In particular, the luminaire has at least one elastic element. This element can be designed such that the reflector and the light module can be tensioned against each other at their contact points via their positioning surfaces, especially during pre-assembly. For example, the elastic element can be attached to the reflector and engage in an opening that may be provided in the light module. Alternatively, the light module can also contain the elastic element. For example, the elastic element can be a leaf spring that tensions the positioning surfaces against each other in the pre-assembled or assembled state. It is advantageous to pre-tension the positioning surfaces against each other via the elastic element, as this makes it easy to position the reflector and the light module relative to each other during assembly.Furthermore, during pre-assembly of the light module on the reflector, the elastic element ensures that the positioning is maintained. The elastic element pre-tensions the reflector and the light module via the positioning surfaces, preferably at least in the first spatial direction, i.e., for example, in the longitudinal direction of the vehicle. However, it is also possible for the elastic element to pre-tension the components against each other via the positioning surfaces at least in the second spatial direction. Preferably, the elastic element and the positioning surfaces are designed and arranged such that the reflector and the light module are pre-tensioned in one plane – particularly during pre-assembly – with the plane preferably being spanned by the first and second spatial directions.It is also conceivable that the force that can be applied via the elastic element is temporarily applied by a manufacturing device for the duration of the screwing or assembly process and is removed again after the fasteners are secured. Since the screw has taken over the force transmission, the spring force of the elastic element is no longer necessary.

[0020] In a preferred embodiment, the reflector or light module has at least one projection, such as a pin. The projection can include the at least one positioning surface of the reflector or light module. Preferably, the projection extends in the third spatial direction, that is, in particular, in the vertical direction of the vehicle. A portion of an outer circumferential surface of the projection is preferably the positioning surface. In particular, the projection is provided on the reflector. For example, the projection can extend in the third spatial direction away from the reflector in the form of a pin. The portion of the outer circumferential surface of the projection that includes the positioning surface can be formed in the same mold half of an injection mold as the reflective surface. The remaining portion of the projection can be formed in at least one other mold half.

[0021] The projection, which includes the positioning surface, can extend, in particular, from the upper surface of the reflector. The projection preferably extends from a section of the reflector that extends away from the reflective surface. This section preferably extends in a plane that encompasses the first and second spatial directions. This is advantageous because it allows the light module to be easily attached to the reflector in such a way that the light from the light module can be reflected off the reflective surface. The projection can, in particular, extend on the side of the section facing away from the reflective surface. To enable the light from the light module to be emitted onto the reflective surface, the section extending away from the reflective surface can have an opening or a passage through which the light from the light module can be emitted.On the side of the section from which the projection extends, facing the reflector, the projection can also be reflective. This is advantageous because it increases the efficiency of the luminaire. The position of the projection on the reflector can be chosen such that the part of the projection containing the positioning surface can be manufactured in the same mold half as the reflective surface.

[0022] The reflector or light module preferably has at least one recess that can contain the at least one positioning surface of the reflector or light module. The projection can be inserted into the recess. A portion of an inner circumferential surface of the recess can be configured as the at least one positioning surface. Preferably, the light module has the recess. The recess can, for example, be easily machined into the light module by milling or another subtractive manufacturing process.

[0023] By integrating the positioning surfaces into the recess and the projection, positioning can be carried out quickly and easily by inserting the projection into the recess. For example, this allows positioning to be performed automatically.

[0024] In a preferred embodiment, the reflector and the light module each have at least two positioning surfaces. That is, the reflector can have at least two recesses or at least two projections. However, it is also possible for the reflector to have at least one recess and at least one projection, and for the light module to also have at least one recess and at least one projection, wherein the projection of each component, i.e., the reflector and the light module, can be inserted into the recess of the other component. In a preferred embodiment, the reflector has at least two projections, and the light module has at least two recesses into which the projections of the reflector can be inserted.

[0025] Preferably, the reflector has two cylindrical projections, particularly circular cylindrical ones. In other words, the reflector preferably has two pins. The projections can extend parallel to each other. Preferably, the pins extend in the third spatial direction and from approximately the same height in that direction. Preferably, in the section encompassing the first and second spatial directions, the pins extend from the reflective surface to the same length.

[0026] Preferably, the V-shaped positioning surfaces are formed in one recess, and a further positioning surface is formed in another recess. A projection interacts with the V-shaped positioning surfaces via its circumferential surface, and a further projection interacts with the further positioning surface. The projection, or each projection, is preferably spaced away from the recess except for the contact point of its positioning surface(s) in the assembled or pre-assembled state of the reflector and the light module.

[0027] The reflector and the light module preferably each have at least one further positioning surface by which the reflector can be positioned relative to the light module in the third spatial direction, which is perpendicular to the plane defined by the first two spatial directions. In particular, the positioning surfaces by which the reflector can be positioned relative to the light module in the third spatial direction extend parallel to the plane containing the first and second spatial directions. This is advantageous because the reflector can thus be positioned relative to the light module in the three spatial directions in a device-technical manner. The at least one further positioning surface of the reflector can be produced together with the reflective surface and the at least one positioning surface, which can be manufactured together in the mold half.However, it is also possible that at least one further positioning surface of the reflector, which is configured to position the reflector to the light module in the third spatial direction, can be produced in a second mold half.

[0028] The light module preferably comprises at least one light source, preferably an LED or an LED array, whose light can be reflected by the reflector's reflective surface. Furthermore, the light module preferably comprises at least one circuit board with which the light source can be connected for power supply. To dissipate heat generated when the light module emits light, a heat sink is preferably provided, on which the circuit board and the LED can be arranged. The heat sink preferably has at least one positioning surface, i.e., preferably at least one recess or at least one projection. Because the heat sink of the light module has the positioning surface, the light module can be designed very compactly, as no additional component with the positioning surface of the light module is required. This also allows the luminaire to be manufactured cost-effectively.

[0029] In particular, the heat sink can also have an additional positioning surface via which the reflector can be positioned relative to the light module in the spatial direction that extends perpendicular to the plane defined by the two spatial directions, i.e., in the third spatial direction. This positioning surface, via which the reflector can be positioned relative to the light module in the third spatial direction, can optionally be provided from a projection of the heat sink.

[0030] Preferably, a fastening means is provided for fixing the light module to the reflector. This means is designed such that the reflector and the light module are connected by force, material, and / or form-fitting, particularly after pre-assembly. For example, the light module can have at least one opening, in particular a through-hole. This opening extends in the third spatial direction. A screw or other fastening means can be inserted into the opening, allowing the light module to be attached to the reflector. The light module can then be clamped between the screw head and the reflector. However, it is also possible to use other fastening elements to attach the light module to the reflector.For example, a snap-fit ​​connection can be used, or the light module can be bonded to the reflector after the light module has been aligned with the reflector via the positioning surfaces. An inner circumferential surface of the opening is preferably designed to allow clearance relative to the outer surface of the fastener. This prevents the light module from being moved from its pre-assembled position when, for example, the screw is inserted and tightened. Furthermore, the reflector preferably has a threaded receptacle for the screw. The light module preferably has a bearing surface for the screw head.

[0031] The reflector can, for example, be designed as a shell. In particular, the reflective surface is free-form. At least part of a concave inner surface of the shell can form the reflective surface. The reflective surface can be formed, at least partially, from reflector facets. The reflector facets can, for example, be arranged side by side in the second spatial direction or in the transverse direction of the vehicle if the reflector is installed in a vehicle. The shell preferably has an outer mounting side that faces upwards if the reflector is installed in a vehicle. The mounting side serves for mounting the light module. The mounting side may include, for example, the projection(s) and / or the elastic element and / or the threaded receptacle. The mounting side may have a light aperture through which the light module can emit light onto the reflector surface.The main direction of emission for the light of the light module can preferably be the third spatial direction, wherein the light shines downwards in the mounted state of the light module before it hits the reflective surface.

[0032] According to the invention, a tool for manufacturing the reflector is also provided, wherein the tool has at least two mold halves. The tool is designed such that the reflective surface, or at least a part of the reflective surface of the reflector, and the at least one positioning surface of the reflector can be manufactured in a common mold half, which is formed in one piece and / or continuously. However, it is also possible for the tool to have three or more mold halves, as long as the reflective surface and the at least one positioning surface of the reflector are formed in a common mold half. If several, preferably three, positioning surfaces are provided for the light module in the reflector, these can preferably all be formed in the common mold half.

[0033] The tool is preferably made of metal. In particular, it can be made of steel. In a preferred embodiment, the tool is an injection mold.

[0034] Furthermore, a vehicle equipped with a reflector or light is provided. The vehicle can be an aircraft, a watercraft, or a land-based vehicle. The land-based vehicle can be a motor vehicle, a rail vehicle, or a bicycle. A truck, a passenger car, or a motorcycle is particularly preferred. The vehicle can also be configured as a non-autonomous, semi-autonomous, or autonomous vehicle.

[0035] The at least one light source of the luminaire can be configured as a light-emitting diode (LED), and / or as an organic LED (OLED), and / or as a laser diode, and / or as a light source operating according to the Laser Activated Remote Phosphor (LARP) principle, and / or as a halogen lamp, and / or as a gas discharge lamp (High Intensity Discharge (HID)), and / or in conjunction with a projector operating according to the Digital Light Processing (DLP) principle. Thus, a multitude of alternatives are available as a light source for the luminaire according to the invention.

[0036] Furthermore, a method for manufacturing the luminaire is provided. In this method, the light module is first positioned relative to the reflector for pre-assembly by aligning the positioning surfaces of the reflector and the light module. The positioning surfaces, particularly those with an elastic element, can then be clamped against each other to prevent them from shifting during or after assembly. The force applied to clamp the positioning surfaces can also be supplied by an external device, such as a manufacturing fixture. The positioning surfaces can be aligned and clamped simultaneously. Alternatively, they can be aligned first and then clamped against each other in a subsequent step.This is advantageous because it ensures that the positioning of the light source relative to the reflector can be maintained even while the luminaire is in operation. The light module is then attached to the reflector using the mounting hardware for final assembly.

[0037] The invention also relates to a light module according to one of the embodiments already mentioned or listed below.

[0038] The invention will now be explained in more detail using exemplary embodiments. The figures show: Fig. 1 a perspective partial view of a reflector and a perspective partial view of one half of a mold of a tool with which the reflector can be manufactured, Fig. 2 a top view of an area of ​​the reflector to which a light module can be attached, Fig. 3 a perspective view of a light module according to an embodiment of the invention, Fig. 4 a perspective view of a lamp with the reflector and the light module, Fig. 5 a top view of the area which is in Fig. 2 is shown, with light module, Fig. Figure 6 shows an enlarged top view of a plane in which the reflector can be positioned relative to the light module, with the attachment points shown. Fig. 7 a perspective view of a light module according to a further embodiment of the invention and Fig. 8 A flowchart of a procedure for assembling a light fixture.

[0039] In Fig. Figure 1 shows a reflector 1 which has a reflective surface 2 on which the light of a light module, which is not shown here, can be reflected.

[0040] The reflective surface 2 of the reflector 1 is bowl-shaped and can be divided into three areas. A first reflective surface area 4 extends in a plane containing a first spatial direction X and a third spatial direction Z. The first spatial direction X, a second spatial direction Y, and the third spatial direction Z are each perpendicular to one another. If the reflector is located in a vehicle 5, which is represented here by a dashed line, the first spatial direction X can be a longitudinal direction of the vehicle 5, the second spatial direction Y can be a transverse direction of the vehicle 5, and the third spatial direction Z can be a vertical or upward direction of the vehicle. The reflective surface area 4 is a side wall and is a shell-shaped side surface of the bowl-shaped reflector 1.A further reflective surface area 6 extends in a plane that contains the first spatial direction X and the second spatial direction Y. When the reflector 1 is arranged in the vehicle 5, the reflective surface area 6 is a reflector underside or shell underside. A further reflective surface area 8, which is connected to the reflective surface areas 4 and 6, is approximately spherical segment-shaped or concave and is laterally bounded by the reflective surface area 4 and downwardly bounded by the reflective surface area 6. The reflective surface areas 4 and 6 project away from the reflective surface area 8, each projecting in the first spatial direction X or forward in the longitudinal direction of the vehicle towards the front of the vehicle 5.

[0041] The reflector 1 also includes a mounting section 10, which extends from the reflective surface area 8 on the upper surface of the reflector 1 and which has a mounting structure. The reflective surface area 8 extends essentially in a plane that contains the first spatial direction X and the second spatial direction Y. Furthermore, the mounting section 10 extends from the reflective surface area 8 essentially towards the rear of the vehicle 5. The mounting section 10 has a light module mounting area 12, to which the light module can be attached, which is located essentially in the center of the mounting area 10. The mounting section 10 also has a further mounting area 14, with which the reflector 1 can be attached to other components, such as a headlight housing, which is not shown here.

[0042] The light module mounting area 12 has two projections 16, each of which has a positioning surface which are not marked with a reference symbol here for the sake of clarity.

[0043] In order for the light from the light module to hit the reflective surface 2, an opening 17 is provided in the light module mounting area 12 through which the light can shine.

[0044] Furthermore, the reflector 1 has an opening 18 in the light module mounting area 12, which is a through-hole, through which the light module can be attached to the reflector 1, for example by inserting a screw as a fastening element. In particular, the opening 18 has a thread for securing the screw.

[0045] The projections 16 are pin-shaped or web-shaped and extend in the third spatial direction Z away from the light module mounting area 12. That is, they extend upwards in the vehicle 5 in a vehicle vertical direction or vehicle height direction. A portion of each outer circumferential surface of the projections 16 serves as the positioning surface, with this portion pointing essentially forwards in the longitudinal direction of the vehicle, towards the front of the vehicle.

[0046] Furthermore, a mold half 20 of an injection mold is shown. It can be seen that the part of the circumferential surface of the projections 16, which serve as positioning surfaces, can be produced by the mold half 20, as can the reflective surface 2 of the reflector 1. That is, the reflector 1 is designed such that the positioning surfaces arranged on the projections 16 can be produced in a common mold half 20 with the reflective surface 2.

[0047] In Fig. Figure 1 is indicated by arrows showing which part of the reflector 1 can be produced by which part of the mold half 20. The arrows also show the demolding direction of the reflective surface 2 and the projections 16. The arrows show that the projections 16 can be produced section by section by the mold half 20, and that the reflective surface 2 can be produced essentially entirely by the mold half 2.

[0048] Fig. Figure 2 shows a top view of the light mounting area 12 of the reflector 1, which is located in Fig. Figure 1 shows the projections 16 each having an outer circumferential surface 22. A respective part of the outer circumferential surfaces 22, which is indicated by the arrows in Fig. Figure 1 illustrates that the respective positioning surface 23 is formed in the mold half 20. A second part of the circumferential surface 22 of the respective projection 16 can be produced in another mold half, which is not shown.

[0049] The reflector 1 also has further positioning surfaces 24 that extend horizontally, i.e., approximately parallel to the direction of extension of the light module mounting area 12. The light module can be positioned relative to the reflector 1 in the vehicle's vertical direction or in the third spatial direction Z via the positioning surfaces 24.

[0050] Furthermore, the reflector 1 has a leaf spring 25 which serves as an elastic element and which can exert force on the light module, which is not shown here, in such a way that the positioning surfaces 23 can be pre-tensioned against positioning surfaces of the light module.

[0051] Fig. Figure 3 shows a light module 26 according to an embodiment of the invention, which is attached, for example, to the reflector 1 of the Fig. 1. The light module 26 has a circuit board 28 which can be electrically contacted with an LED 30, which serves as a light source. The circuit board 28 and the LED 30 are each mounted on a heat sink 32.

[0052] The heat sink 32 has a first region 34, which extends substantially parallel to a plane, and on which the circuit board 28 and the LED 30 are mounted. Furthermore, it has a second region 36, a third region 38, and a fourth region 40, which extend approximately perpendicularly away from the first region 34 to dissipate heat generated by the LED 30. The regions 36, 38, and 40 extend in a direction away from the side on which the circuit board 28 and the LED 30 are arranged on the heat sink 32. The circuit board 28 and the LED 30 are arranged side by side on the heat sink 32, with the LED 30 positioned near one of the edges of the heat sink 32. Area 36 extends from the edge of the heat sink 32, near which the LED 30 is located, and areas 38, 40 project away from the adjacent edges of it.

[0053] The light module 26 has two positioning surfaces 41 for positioning the light module 26 in the third spatial direction Z on the reflector 1. The positioning surfaces 41 are located on the positioning surfaces 24 in the light module mounting area 12 on the reflector 1.

[0054] In the heat sink 32, in the area 34 on which the circuit board 28 and the LED 30 are arranged, two recesses 42, 44 are provided, into which the projections 16, s. Fig. 2, are insertable. A part of the inner circumferential surfaces 46, 48 of the respective recesses 42, 44 serve as positioning surfaces which can be placed against the positioning surfaces 23 of the projections 16 of the reflector 1.

[0055] Furthermore, the light module 26 has an opening 49, such as a drilled hole, into which a fastening element, such as a screw, can be inserted to attach the light module 26 to the reflector 1. The opening is located in the center of the light module 26 in area 34 and extends through both the circuit board 28 and the heat sink 32.

[0056] Fig. Figure 4 shows a lamp 50, which illuminates the reflector 1, see. Fig. 1, and the light module 26, see. Fig. 3. It can be seen that the light module 26 is mounted in the light module mounting area 12 of the reflector 1. The light module 26 is mounted on the reflector 1 such that the circuit board 28 and the LED 30 face the reflector 1 and that light from the LED 30 shines through an opening in the light module mounting area 12 onto the reflective surface 2 of the reflector 1. The areas 36, 38, 40 of the heat sink 32 point away from the reflector 1.

[0057] In Fig. Figure 5 shows a top view illustrating how the positioning surfaces 23, which are part of the outer circumferential surface 22 of the projections 16, are pre-tensioned against the positioning surfaces 46, 48, which are part of the inner circumferential surface of the recess 42, 44. A projection 52 of the leaf spring 25 engages in an opening 54 of the heat sink 32 of the light module 26 to exert force on the light module 26 such that the positioning surfaces 23 of the reflector 1 bear against the positioning surfaces 46, 48 of the light module 26. The leaf spring 52 pre-tensions the light module 26 in the first spatial direction X, i.e., in the longitudinal direction of the vehicle and towards the front of the vehicle. The positioning surfaces support each other in at least two different directions.If the light module 26 is positioned relative to the reflector 1 via the positioning surfaces 23, 46, 48, a screw, which can serve as a fastening means, can be inserted through the openings 49, 18 of the reflector 1 and the light module 26 in order to detachably, i.e. reversibly, attach the light module 26 to the reflector 1.

[0058] In Fig. Figure 6 shows an enlarged representation of how the positioning surfaces 23, 46, 48 abut each other at three contact points 56, 58, 60. The positioning surface 48 of the recess 44 of the light module 26 is designed as a flat surface extending in the second spatial direction Y and the third spatial direction Z. The positioning surface 23 of the reflector 1 has a semicircular cross-section, i.e., in the plane containing the first spatial direction X and the second spatial direction Y. This allows the positioning surface 23 to abut tangentially with the positioning surface 48.

[0059] The positioning surface 46 of the recess 42 in the heat sink 32 of the light module 26 abuts the positioning surface 23 of the reflector 1 at two contact points 58, 60 in the plane containing the first and second spatial directions X, Y. The positioning surface 46 is designed such that tangents 62, 64 intersect, passing through the contact points 58, 60 where the positioning surfaces 23, 46 abut each other. That is, the contact surface 46 has two surfaces that extend towards each other in a V-shape, and the positioning surface 23 of the reflector 1 abuts each of these surfaces.

[0060] In Fig. 7 shows a light module 66 according to a further embodiment of the invention, which differs from the light module 26 of Fig. 3 differs in that it has projections 68 instead of the recesses 42, 44. The projections 68 extend from the area 34 of the heat sink on one side, where the LED 30 and the circuit board 28 are arranged. The projections 68 are cylindrical, and part of an outer circumferential surface 70 of each projection is designed as a positioning surface 72 for positioning the light module 66 on a reflector, which is not shown here. The reflector on which the light module 66 can be positioned has, in comparison to the reflector 1 of the Fig. 1 recesses instead of the projections 16 into which the projections 68 of the light module 66 can be inserted.

[0061] In Fig. 8 is a step in a procedure for assembling a light fixture, for example the light fixture 50 of the Fig. 4, shown. In a first step 74, at least one positioning surface of a reflector, for example the positioning surfaces 23 of reflector 1, is attached to at least one further positioning surface of a light module, for example to positioning surfaces 46, 48 of a light module 26 of the Fig. 3. To ensure that the positioning of the reflector relative to the light module is not lost, in a further step 76 the positioning surfaces are fitted with an elastic element, such as the leaf spring 25 of the Fig. 2, tensioned against each other. Step 74 and step 76 can be performed simultaneously or sequentially. Afterwards, in a subsequent step 78, the light module is detachably, i.e., reversibly, attached to the reflector. For example, a screw can be inserted as a fastener through the opening 49 of the light module 26 and screwed into the opening 18 of the reflector 1, which may have a thread. Reference symbol list 1 reflector 2 Reflection surface 4, 6, 8 Reflection area 5 vehicles 10 Mounting section 12 Light module mounting area 14 Mounting area 16 lead 17 Opening 18 Opening 20 half of the mold 22 Circumferential area 23 Positioning area 24 positioning areas 25 leaf spring 26 light module 28 circuit boards 30 LED 32 heat sinks 34, 36, 38, 40 area 42, 44 recess 46, 48 Positioning area 49 Opening 50 light 52 Cantilever 54 Opening 56, 58, 60 investment points 62, 64 tangent 66 Light module 68 lead 70 Outer circumferential surface 72 Positioning area Steps 74-78

Claims

[1] Reflector for a luminaire (50) with at least one reflective surface (2) on which light from a light module can be reflected, and with at least one positioning surface (23) via which the light module can be positioned on the reflector (1) in at least one direction or in at least one plane, characterized by , that the reflection surface (2) and the positioning surface (23) are designed and arranged in such a way that they can be manufactured in a common one-piece, form-bound mold half (20) of a tool. [2] Reflector according to claim 1, wherein the reflection surface (2) and the positioning surface (23) are designed such that they can be demolded in a common demolding direction. [3] Reflector according to claim 1 or 2, wherein the reflector (1) can be produced by injection molding. [4] Lamp for a vehicle comprising at least the reflector (1) according to one of claims 1 to 3 and at least one light module (26), wherein light emitted by the light module (26) is reflectable by the reflector (1) and the light module (26) is attached to the reflector (1), wherein the reflector (1) has at least one positioning surface (23) and the light module (26) has at least one further positioning surface (46, 48), wherein the positioning surfaces (23, 46, 48) cooperate to position the light module (26) relative to the reflector (1) and the light module (26) can be positioned in a plane relative to the reflector (1) via the positioning surfaces (23, 46, 48). [5] Luminaire according to claim 4, wherein the positioning surfaces (23, 46, 48) of the light module (26) and the reflector (1) are designed such that the light module (26) is positioned in the plane relative to the reflector (1) via three contact points (56, 58, 60). [6] Luminaire according to claim 4 or 5, wherein the positioning surfaces (23, 46, 48) of the reflector (1) and the light module (26) are designed such that they are tangentially in the plane at the contact points (56, 58, 60). [7] Luminaire according to any one of claims 4 to 6, wherein the reflector (1) or the light module (26) has at least one projection (16) which includes the positioning surface (23, 46, 48) of the reflector (1) or the light module (26), wherein a part of an outer circumferential surface (22) of the projection (26) is the positioning surface (23, 46, 48). [8] Luminaire according to claim 7, wherein the reflector (1) or the light module (26) has at least one recess (42, 44) into which the projection (16) of the light module (26) or of the reflector (1) can be inserted, wherein a part of an inner circumferential surface of the recess (42, 44) forms the positioning surface (23, 46, 48). [9] Luminaire according to any one of claims 4 to 8, wherein the reflector (1) and the light module (26) each have at least two positioning surfaces (23, 46, 48). [10] Luminaire according to one of claims 4 to 9, wherein the reflector (1) and the light module (26) each have a further positioning surface (24, 41) via which the reflector (1) can be positioned relative to the light module (26) in a spatial direction that extends perpendicular to the plane. [11] Luminaire according to one of claims 4 to 10, wherein the light module (26) has a heat sink (32) and a circuit board (28) and at least one light source (30) which can be electrically contacted with the circuit board (28), wherein the heat sink (32) has the at least one positioning surface (46, 48) of the light module (26). [12] Tool for manufacturing the reflector (1) according to one of claims 1 to 3, wherein this tool has at least two mold halves (20), wherein the reflective surface (2) of the reflector (1) and the at least one positioning surface (23) of the reflector (1) can be produced in a common mold half (20) which is formed in one piece. [13] Vehicle with the reflector (1) according to one of claims 1 to 3 or with the light (50) according to one of claims 4 to 11. [14] Method for manufacturing the luminaire (50) according to one of claims 4 to 11, wherein the positioning surfaces of the light module (26) and the reflector (1) are placed against each other for positioning and pre-assembly and the positioning surfaces (23, 46, 48) are clamped against each other, and wherein, following final assembly, the light module (26) is attached to the reflector (1) in its pre-assembled position with respect to the reflector (1) by means of a fastening means. [15] Method according to claim 14, wherein the lamp has an elastic element (25) which exerts a force such that the positioning surfaces (23, 46, 48) of the reflector (1) and the light module (26) are tensioned against each other during pre-assembly and / or wherein a force is exerted via a manufacturing device such that the positioning surfaces (23, 46, 48) of the reflector (1) and the light module (26) are tensioned against each other during pre-assembly.

Images