Light module, motor vehicle lighting device with such a light module and method for mounting an optical system of a light module on a light source module of the light module

Abstract

Light module (2) of a motor vehicle lighting device (100), comprising a light source module (4) with a semiconductor light source (10) mounted on a support element (8) for emitting light (48) and an optical system (6) for deflecting and / or shaping the emitted light (48), wherein the light source module (4) and the optical system (6) are positioned relative to each other in three-dimensional space (x, y, z) by means of a stop and support geometry and then attached to each other, wherein the light module (2) is designed such that, after positioning the light source module (4) and the optical system (6) relative to each other in three-dimensional space (x, y, z), a spring element (50, 52) acts between them to fasten the light source module (4) and the optical system (6) to each other, wherein the spring element (50, 52) is designed to keep the bearing surfaces (32, 40) of the bearing geometry and the stop surfaces (34, 44) of the stop geometry in contact with each other for the duration of the spring action, and the light module (2) is designed such that the spring element (50, 52) acts directly between the light source module (4) and the optical system (6) or a component (56) formed integrally with it, wherein the spring element (50, 52) is rotatably suspended on the light source module (4), in particular on the support element (8) of the light source module (4), or on the optical system (6), wherein the spring element (50, 52) is arranged and designed in the light module (2) such that at the end of the positioning of the light source module (4) and the optical system (6) relative to each other it automatically snaps into a snap-in geometry (58) of the light source module (4) or of the optical system (6), wherein a ramp (60) is formed on the light source module (4) or the optical system (6) to which the spring element (50, 52) is non-rotatably suspended, which extends from an initial position (64) where the spring element (50, 52) rests relative to each other at the beginning of the positioning of the light source module (4) and the optical system (6) to the locking geometry (58), and the ramp (60) is designed such that the spring element (50, 52) slides along the ramp (60) during the positioning of the light source module (4) and the optical system (6) relative to each other, in order to then automatically lock into the locking geometry (58) at the end of the positioning of the light source module (4) and the optical system (6) relative to each other, and wherein the spring element (50, 52) is designed with a spring force (F_V) between the light source module (4) and the optical system (6)which has a supporting force component (F_Auf) in a first direction (x) and a striking force component (F_An) in a second direction (z) perpendicular to the first direction (x).

Description

[0001] The present invention relates to a light module of a motor vehicle lighting device according to claim 1.

[0002] Furthermore, the invention relates to a motor vehicle lighting device, in particular in the form of a motor vehicle headlight, according to claim 4.

[0003] Finally, the invention also relates to a method for mounting an optical system of a light module of a motor vehicle lighting device on a light source module of the light module according to claim 5.

[0004] Modern vehicle headlights are now almost exclusively manufactured using LED technology. This addresses both the ever-increasing demands for energy savings and improved lighting, while maintaining a modern design.

[0005] The LEDs used in vehicle headlights are typically high-power SMD LEDs, which are either soldered directly onto a circuit board (PCB) or, to improve heat dissipation, mounted directly onto a heat exchanger (heat sink). Good thermal contact is essential to efficiently dissipate the LED's heat and prevent damage or a shortened lifespan due to thermal stress. The system's lifespan and stability must be designed to ensure maintenance-free operation throughout the vehicle's entire lifespan. Replacing faulty LED light sources or optical components is currently not technically possible in LED headlights available on the market and is therefore not intended.

[0006] From DE 10 2016 119 792 A1, a light module is known in which a light source module comprises a semiconductor light source mounted on a circuit carrier and a heat sink on which the circuit carrier with the semiconductor light source is arranged. An optical system, e.g., in the form of a reflector, is positioned relative to and attached to the light source module by means of a stop and support geometry. The stop and support geometry acts between the optical system and the circuit carrier. The support geometry includes support ribs formed on a base surface of a mounting socket of the optical system facing the circuit carrier. These ribs interact with corresponding support areas of the circuit carrier to position the semiconductor light source mounted on the circuit carrier relative to the optical system in a first x-direction.The stop geometry comprises several stop elements in the form of stop pins, which are attached to the circuit carrier depending on the position of the semiconductor light source. These pins bear against corresponding stop surfaces formed on an end face of the mounting base of the optical system in order to position the semiconductor light source and the optical system relative to each other in a yz-plane perpendicular to the first direction. A screw, for example, is provided for attaching the reflector to the circuit carrier. Reference is expressly made to DE 10 2016 119 792 A1 with regard to the design of the stop and support geometry. This document is expressly incorporated into the present application with regard to the design of the stop and support geometry.

[0007] Another type of stop and support geometry is described in a further application filed concurrently with the present application by the same applicant (inventor: Pfitzner, Bartsch; DE 10 2022 108 281 A1). This further application is expressly referenced with regard to the design of the stop and support geometry. This further application is expressly incorporated into the present application with regard to the design of the stop and support geometry.

[0008] From US patent 2015 / 308652 A1, a light module is known that comprises an optical system in the form of a reflector and a heat sink to which the reflector is attached by screws. The light module further includes a separate adapter element with cooling fins, a circuit carrier, and a semiconductor light source mounted thereon. The adapter element is positioned relative to the heat sink of the heat sink-reflector combination by means of a positioning geometry and then attached to it by means of a spring element. The positioning geometry includes contact surfaces for positioning the adapter element or the semiconductor light source relative to the heat sink or the reflector in a first direction (x).Furthermore, the positioning geometry on the heat sink includes positioning pins that engage with positioning holes in the circuit carrier of the adapter element, ensuring positioning in a plane (y, z) perpendicular to the first direction (x). However, the contact surfaces only become active after the adapter element has been positioned relative to the heat sink-reflector combination in the plane (y, z). Moreover, this document does not concern the positioning and mounting of an optical system to a light source module, but rather the positioning and mounting of the adapter element to the heat sink-reflector combination.

[0009] A light module and a motor vehicle lighting device of the type described above are known, for example, from US 2018 / 0031194 A1, which represents the closest prior art. Similar light modules and motor vehicle lighting devices are also known from DE 21 2019 000 443 U1 and DE 10 2012 219 007 A1. Further prior art is known in the form of DE 20 2018 107 292 U1 and WO 2014 / 190 368 A1.

[0010] Finally, a light module is known from AT 513 362 A1, in which an optical system in the form of a reflector is positioned relative to a light source module. This system comprises a semiconductor light source mounted on a circuit carrier and a heat sink on which the circuit carrier with the semiconductor light source is attached. The reflector is then attached to the light source module. For attaching the reflector to the light source module, for example, two fastening elements in the form of spring clips are provided, which are clipped laterally onto a mounting base of the reflector and the heat sink of the light source module. The springs must be guided through and hooked into slot-shaped openings formed laterally in the mounting base of the reflector. This makes attaching the reflector to the light source module time-consuming and complicated.In particular, after positioning the reflector relative to the light source module, an additional step is required, which must be carried out manually, to hook the springs into the slot-shaped openings of the reflector and then clip them over the light source module.

[0011] A further problem with the spring clips used in AT 513 362 A1 is that they only act in the first direction (x). Thus, while the spring clips can keep the contact surfaces of the support geometry acting in the first direction (x) in contact with each other for the duration of the spring action, they cannot keep the contact surfaces of the stop geometry acting perpendicular to it in the plane (y, z). For this purpose, AT 513 362 A1 provides an additional spring element, integrally formed with the reflector, which is supported by a section of the heat sink and acts in a second direction (z), perpendicular to the first direction (x), between the reflector and the heat sink. A support for the reflector relative to the light source module, acting in a third direction (y) perpendicular to the first and second directions (x, z), is not provided.

[0012] A major challenge in vehicle headlights is positioning the optical components, such as light sources, reflectors, lenses, and mirror baffles, in large quantities, using simple and therefore cost-effective methods, with the required accuracy relative to each other, and then precisely fixing their positions. Even slight deviations from tolerances can lead to significant light loss, potentially resulting in an illegal light distribution on the road because it no longer complies with regulations. A key aspect is the precise positioning of the light source module, which typically consists of LED light source(s), a circuit board (possibly with a connector), and a support element (e.g., a heat sink), relative to the optical system, such as a reflector, lens, optical element, or light guide. In currently available systems, the components are usually screwed together after positioning.The highly accurate positioning at the end of the positioning of the light source module relative to the optical system is subsequently also referred to as achieving the relative position.

[0013] Fastening using screws has the following disadvantages: - Screwdriver required to operate the screw(s), - a special device is required to ensure the relative position of the components before and during the screwing process (this is usually done by means of a mounting device that ensures the contact of the reference geometries (stop and support geometries) of the components during screwing), - there is a risk of contamination from particles that arise during thread cutting / thread forming in the reflector material (e.g. a thermoset) during the screwing process (this requires special measures for particle extraction / collection during assembly), - Assembly is time-consuming and requires an additional step for screwing in the screw(s), Replacing the light source module (e.g., in the case of an aged or defective semiconductor light source) is not easily possible, as after disassembly and removal of the old light source module, the new light source module must be reinstalled in / with a mounting device, and - A complex reflector tool with slide demolding is required to demold the screw dome.

[0014] Based on the described prior art, the present invention is therefore based on the objective of proposing a technical possibility of attaching the optical system of a light module of the type mentioned above simply, cost-effectively and efficiently to the light source module after positioning it relative to the latter, thereby avoiding the disadvantages of the prior art listed above.

[0015] To solve this problem, a light module with the features of claim 1 is proposed. In particular, starting from the light module of the type mentioned above, it is proposed that after positioning the light source module relative to the optical system in three-dimensional space (x, y, z), a spring element acts between the light source module and the optical system, which is configured to keep both the bearing surfaces of the bearing geometry and the stop surfaces of the stop geometry in contact with each other for the duration of the spring action.

[0016] The core of the present invention is to achieve a robust attachment of a light source module to an optically effective system, such as a reflector, by means of a spring element. The invention enables assembly without the need for tools or mounting devices. The precise positioning of both components relative to each other is ensured by this invention throughout the entire service life of the light module or the vehicle, as the spring element, through its permanent tension, guarantees contact between the contact surfaces / reference surfaces of both components. It is particularly important that the spring element ensures contact between both the bearing surfaces of the mounting geometry (in a first direction) and the contact surfaces of the stop geometry (in a plane extending perpendicular to the first direction) for the entire service life.Furthermore, the mounting is quick and easy to release, even if access to the spring element inside the housing of the vehicle lighting unit is difficult. This allows the light source module to be easily replaced during servicing.

[0017] Compared to the fastening method using screws, which has been used in practice so far, the following advantages result: - No assembly tools required, - No mounting device required, - no risk of a change in position (displacement / rotation) of the optical system and light source module relative to each other due to the screwing process and the torque introduced thereby, - easy to assemble / disassemble, thus allowing for good interchangeability of the light source module, - Incorrect assembly of the optical system and light source module relative to each other is virtually impossible or is detected immediately (if the spring element does not reach its end position in which it develops its full spring effect, or if the light source module / spring element is not locked in place, then the spring element does not hold and falls back down), - faster assembly process, which leads to an economic advantage, and - No slides are required in the reflector tool for demolding the screw dome, resulting in more economical reflector tool manufacturing.

[0018] The spring element acts directly between the light source module and the optical system or a component integrally formed with it. This means the spring element acts directly on the optical system or a component integrally formed with it. If the spring element were to act on the optical system only indirectly via another component, the connection of the optical system to this component would negatively impact the tolerance chain between the light source module and the optical system. Furthermore, the optical system would only be secured to the light source module via the other component. A loosening or even complete disconnection of the connection between the other component and the optical system could result in the optical system no longer being securely held to the light source module.In particular, this could lead to the contact surfaces of the mounting geometry between the optical system and the light source module, and / or the contact surfaces of the stop geometry between the optical system and the light source module, no longer being held in the desired position. All these problems can be prevented through further training.

[0019] According to a preferred embodiment of the invention, it is proposed that the spring element be designed as a clamping spring. The clamping spring can be designed as a clamping element that is attached to one of the two components, the light source module or the optical system, and holds the other component in the reference position, for example, by means of preload. In this position, both the bearing surfaces of the support geometry and the stop surfaces of the stop geometry are in contact with each other for the duration of the spring action. The clamping spring can act on the other component or via a component formed integrally with the other component. However, it is also conceivable that the clamping spring acts without preload and only achieves the desired spring action when it acts on the other component.

[0020] It would be conceivable, but not the subject of the present invention, for the spring element to be rotatably suspended on the light source module, in particular on the support element of the light source module, or on the optical system. If the spring element is designed, for example, as a bow spring, it can be shaped such that it has two opposite ends arranged on a common axis of rotation and inserted into corresponding recesses or holes in the light source module or the optical system, so that the bow spring is rotatably suspended on the light source module or the optical system. It is particularly preferred that the spring element be rotatably suspended on the light source module, in particular on the support element of the light source module.

[0021] According to the invention, a locking geometry is formed on the light source module or the optical system to which the spring element is non-rotatably attached, and the spring element is designed to lock into the locking geometry at least for the duration of the spring action. The locking geometry can be provided directly on the light source module or the optical system, or on a component formed integrally with it. Preferably, the locking geometry is formed on the optical system or a component formed integrally with it. The spring element can lock into the locking geometry as soon as the components of the light module, the light source module and the optical system, have reached their relative position.

[0022] The spring element automatically and / or autonomously engages in the locking position after the components have reached the relative position. Accordingly, it is proposed that the spring element be arranged and designed within the light module such that, at the end of the positioning of the light source module relative to the optical system, it automatically engages in the locking geometry of the light source module or the optical system.

[0023] The automatic engagement of the spring element after the components have reached the relative position can be achieved in various ways. According to the invention, it is proposed that a ramp be formed on the light source module or the optical system to which the spring element is non-rotatably suspended. This ramp extends from an initial position, where the spring element rests at the beginning of the positioning of the light source module relative to the optical system, to the engagement geometry. The ramp is designed such that the spring element slides along it during the positioning of the light source module and the optical system relative to each other, and then automatically engages in the engagement geometry at the end of the positioning of the light source module and the optical system relative to each other, i.e., after the components have reached the relative position.Preferably, the ramp is provided on the optical system or on a component formed integrally with it.

[0024] According to the invention, it is further proposed that the spring element be configured to exert a spring force between the light source module and the optical system for the duration of the spring action. This spring force has a component in a first direction (x) and a component in a second direction (z) perpendicular to the first direction (x). According to this embodiment, a spring force with force components in two mutually perpendicular directions can be exerted using one and the same spring element. The force component in the first direction (x) can be used to keep contact surfaces of a support geometry in contact with each other. The force component in the second direction can be used to keep contact surfaces of a stop geometry in contact with each other.If at least one of the contact surfaces of the contact geometry in a plane (y, z) perpendicular to the first direction (x) has a surface component in the second direction (z) and in a third direction (y) perpendicular to the first and second directions, the light source module and the optical system can be held in the relative position by the contact force component in the second direction (z) in both the second direction (z) and the third direction (y).

[0025] The problem underlying the present invention is also solved by a motor vehicle lighting device with the features of claim 5. In particular, it is proposed that the at least one light module of the motor vehicle lighting device of the type mentioned at the outset is a light module according to the invention. One or more light modules according to the invention can be arranged inside a housing of the motor vehicle lighting device. The light module(s) according to the invention can be configured to generate a defined light distribution (e.g., low beam, high beam, partial high beam, fog light) or a part thereof (e.g., low beam spot, low beam base light, high beam spot, high beam base light). Furthermore, one or more conventional light modules can also be provided inside the housing. These can be configured to generate a defined light distribution (e.g., a headlight function or a lighting function, e.g.,to produce turn signals, daytime running lights, position lights, taillights, brake lights) or a part thereof (e.g. low beam spot, low beam base light, high beam spot, high beam base light).

[0026] The semiconductor light source can comprise one or more light-emitting diodes (LEDs) or semiconductor laser diodes (SLEDs). The optical system can comprise a reflector, a lens, an optical body, or a light guide. The optical system serves to shape and / or deflect at least a portion of the light emitted by the semiconductor light source. In the case of a reflector, a reflective surface must be positioned relative to the light source of the light source module. In the case of a lens, optical body, or light guide, a light-intake surface must be positioned relative to the light source of the light source module. The support element preferably comprises a heat sink. The optical system, particularly in the form of a reflector, does not include any heat exchanger elements, such as cooling fins, cooling pins, or the like.

[0027] The problem underlying the present invention is also solved by an assembly method with the features of claim 5. In particular, starting from the method of the type mentioned at the outset, it is proposed that the fastening of the light source module and the optical system to one another comprises a step in which a spring element is activated which keeps both the bearing surfaces of the bearing geometry and the stop surfaces of the stop geometry in contact with each other for the duration of the spring action.

[0028] According to the invention, it is proposed that the spring element be brought into action directly between the light source module and the optical system or a component formed integrally with it. The spring element automatically and / or autonomously engages in the locking position after the components have reached the relative position.

[0029] It is proposed that the spring element is automatically activated at the end of the positioning of the light source module relative to the optical system by automatically snapping into a locking geometry of the light source module or the optical system at the end of the positioning of the light source module relative to the optical system.

[0030] Further features and advantages of the present invention are explained in more detail below with reference to the figures, which show preferred embodiments. The individual features shown in the figures may each be essential to the invention on their own, even if this is not shown in the figures and not expressly mentioned in the description. Furthermore, features from different figures can be combined with one another in any way, even if such a combination is not shown in the figures and not expressly mentioned in the description. The figures show: Fig. 1 a light module according to the invention of a motor vehicle lighting device according to a preferred embodiment in a perspective view, Fig. 2 an optical system in the form of a hemispherical reflector of the light module made of Fig. 1 in a perspective view, Fig. 3 the optical system Fig. 2 in a side view, Fig. 4 a light source module of the light module Fig. 1 in a perspective view, Fig. 5 a first snapshot of a method according to the invention for assembling the optical system from the Fig. 2 and Fig. 3 on a light source module Fig. 4, Fig. 6 a second snapshot of the procedure for assembling the optical system from the Fig. 2 and Fig. 3 on a light source module Fig. 4, Fig. 7 a third snapshot of the procedure for assembling the optical system from the Fig. 2 and Fig. 3 on a light source module Fig. 4, Fig. 8 a force triangle of a spring element of the light module made of Fig. 1, Fig. 9 a first detail of a first contact surface of the light source module made of Fig. 4, Fig. 10 a second detail of a second contact surface of the light source module made of Fig. 4, Fig. 11 a motor vehicle lighting device according to the invention in the form of a motor vehicle headlight, and Fig. 12 a flowchart of a method according to the invention for assembling the optical system from the Fig. 2 and Fig. 3 on a light source module Fig. 4.

[0031] A light module according to the invention for a motor vehicle lighting device according to a first embodiment is in its entirety in Fig. 1, designated by reference numeral 2. The light module 2 comprises a light source module 4 and an optical system 6. In the illustrated embodiment of the Fig. 1 The light source module 4 comprises a carrier element 8, one or more semiconductor light sources 10 and a circuit carrier 12. The light source 10 can comprise one or more light-emitting diodes or semiconductor laser diodes.

[0032] The light module 2 can be arranged either alone or together with other light modules 102, which can be designed like the light module 2, inside a housing 104 of the motor vehicle lighting device 100 (see Figure 1). Fig. 11) The housing 104 is designed for installation in a corresponding mounting opening on a motor vehicle body. The lighting device 100 can be – as in Fig. Figure 11 shows the lighting device 100 as a motor vehicle headlight or any motor vehicle light, e.g., a taillight. The housing 104 of the lighting device 100 has a light-emitting opening 106 through which light emitted by the light module 2 passes. The light-emitting opening 106 can be closed by a cover plate 108 made of a transparent material. The cover plate 108 can be a clear plate without optically active elements or a diffusing plate with optically active elements (e.g., cylindrical lenses, prisms) for diffusing the transmitted light. However, it would also be conceivable that the light-emitting opening 106 is not closed by a separate cover plate 108. In this case, for example, an optical system 6 of the light module 2, which is designed as a lens, in particular as a projection lens, could be arranged in the opening 106 and close it.

[0033] The lens would therefore form an outer termination of the lighting device 100 or the housing 104.

[0034] In this example, optical system 6 comprises the Fig. 1. A reflector 14, in particular a hemispherical reflector, with a reflective surface 16 facing the semiconductor light source 10. Alternatively or additionally, the optical system 6 can also comprise a light-shaping optical body, a lens and / or a light guide, each having a light-entry surface facing the semiconductor light source 10. The reflector 14 or its reflective surface 16 deflects light emitted from the semiconductor light source 10 in a main emission direction 48, preferably into a light exit direction 18 of the light module 2 (corresponding to the z-direction).

[0035] In the example shown, the support element 8 includes a heat sink 20 for dissipating waste heat generated during the operation of the semiconductor light source 10. The heat sink 20 can be, for example, as shown in Fig. Figure 1 shows the heat sink 20 bent from a sheet of metal. Alternatively, the heat sink 20 can also be milled from a block of metal or formed as a metal casting. The material of the heat sink 20 is preferably selected to have a good thermal conductivity. It is conceivable that the lighting device 100 has a common support element 8 for several light modules 2.

[0036] The circuit carrier 12 comprises conductive traces, preferably part of a circuit unit (e.g., printed circuit board, PCB), which connect a connector element 22 to contact traces 24 (e.g., in the form of bonding wires) via which the semiconductor light source 10 is electrically contacted. The light module 2, in particular the semiconductor light source 10, can be connected via the connector element 22 to a power supply of the vehicle and / or to a control unit of the light module 2 or the lighting device 100. The circuit carrier 12 can be attached to the support element 8 without requiring any special accuracy. The circuit carrier 12 is attached to the support element 8 using suitable fasteners, such as adhesive, screws, or rivets, to name just a few.

[0037] The semiconductor light source 10 can be attached to the support element 8 either directly or indirectly, for example, via another circuit carrier. The semiconductor light source 10 is attached to the support element 8 using suitable fasteners, such as adhesive or a welded or soldered connection. The attachment of the semiconductor light source 10 to the support element 8 should be carried out with high precision in a predetermined mounting position, if possible. Alternatively, the semiconductor light source 10 could be attached to the circuit carrier 12. In this case, the mounting of the circuit carrier 12 to the support element 8 should also be carried out with high precision in a predetermined mounting position. This is recommended to ensure that the reflective surface 16 is positioned in a predetermined relationship to the semiconductor light source 10 when the optical system 6 is subsequently positioned relative to the support element 8.

[0038] The highly precise positioning and mounting of the semiconductor light source 10, or alternatively the circuit carrier 12 with the semiconductor light source 10 mounted thereon, on the carrier element 8 can be carried out in a manner known per se. For example, a light-emitting surface of the semiconductor light source 10 can first be optically detected and evaluated using a camera. The geometric center, the brightest area or point, and / or edges of the light-emitting surface can be detected. Detection can be performed with the semiconductor light source 10 activated (while it is emitting light) or with the semiconductor light source 10 deactivated. When detecting with the semiconductor light source 10 deactivated, the light-emitting surface is preferably illuminated with external light, the frequency of which preferably corresponds to the frequency of the light emitted by a converter material of the semiconductor light source 10. The converter material emits, for example,When illuminated with blue light from an LED, yellow light is emitted, which mixes with the blue light from the LED to form white light from the semiconductor light source 10. In this case, the external light can also be blue light with a wavelength range of approximately 430-490 nm. However, other frequency ranges of the external light are also conceivable.

[0039] The deactivated semiconductor light source 10, or rather its converter material, is thus preferably irradiated with external light of a wavelength emitted by the LED chip. Therefore, external light of a wavelength corresponding to the excitation frequency of the converter material is used. The light emitted by the converter material is observed and evaluated. Illuminating the converter material with external light of the wavelength emitted by the converter material does not necessarily lead to an improvement in the detection contrast.

[0040] Depending on the result of the evaluation, the semiconductor light source 10 or the circuit carrier 12 with the semiconductor light source 10 attached to it can be positioned with high precision relative to the carrier element 8 and attached to it directly or indirectly.

[0041] One challenge with such light modules 2 is positioning the optical components relative to each other with the required accuracy. Even slight deviations from the correct tolerances can lead to significant reductions in light output, potentially resulting in an illegal light distribution on the roadway that no longer complies with regulations. Particular attention must be paid to the positioning of the light source module 4 or the semiconductor light source 10 relative to the optical system 6, a reflective surface 16 of the reflector 14, or a light-entry surface of a lens, optical body, or light guide. The present invention proposes a specific design of a support and stop geometry that allows the light source module 4 or the semiconductor light source 10 to be positioned relative to the optical system 6 in a simple and cost-effective manner, yet with high precision.

[0042] The optical system 6 can have a side or base surface 26 facing the light source module 4 (see Fig. 2 and Fig. 3) In the optical system 6, designed as a reflector 14, the base surface 26 can be formed by a mounting base 28 of the reflector 14. In the example shown, the reflector 14 has several, preferably two, support ribs 30 on its base surface 26. The support ribs 30 preferably extend at a distance from each other and parallel to one another. Particularly preferably, the support ribs 30 extend parallel to the light emission direction 18 of the light module 2. A relationship between the optical system 6 and the light source module 4 is established via these support ribs 30, so that a position of the optical system 6 in a first spatial direction x relative to the light source module 4 is defined.

[0043] In the example of the Fig. 2 and Fig. The support ribs 30 comprise, firstly, a support geometry 32, which can, for example, be configured as first bearing surfaces on the side of the support ribs 30 facing the light source module 4 (or facing away from the optical system 6). Secondly, in a front region pointing in the direction of light emission 18, the support ribs 30 comprise a stop geometry 34, which is formed, for example, by first stop surfaces of several, preferably two, projections 36 that are formed on the base surface 26 and project from it in the direction of the light source module 4 (away from the optical system 6). The stop geometry 34 is preferably perpendicular to the support geometry 32. Alternatively, the support ribs 30, which form the first bearing surfaces 32, can also be configured separately from the projections 36, which form the first stop surfaces 34.

[0044] At least one of the first stop surfaces 34 is preferably arc-shaped, in particular circular arc-shaped, or wedge-shaped when viewed in the yz-plane. For the other first stop surface 34, it is sufficient if it forms only one stop, preferably a flat or planar stop, in one spatial direction, in particular in the z-direction. The other first stop surface 34 preferably extends in an xy-plane. The bearing surfaces 32 preferably extend in a yz-plane.

[0045] The reflector 14, for example, can be manufactured very easily using an injection molding process. The reference surfaces 32 and 34 can be produced using the same mold half as the reflective surface 16 and demolded without a slide. This ensures very small tolerances between the reflective surface 16 and the reference surfaces 32 and 34. A particular advantage is that the reference surfaces 32 and 34 are not located deep within a mold cavity, but are easily accessible and therefore very simple and cost-effective to adjust.

[0046] The light source module 4 advantageously has several, preferably two, second contact surfaces 40 on a side 38 of the support element 8 or the heat sink 20 facing the optical system 6 (cf. Fig. 4) In the example shown, these are formed by the bottom of the recesses 42. The second support surfaces 40 interact with the first support surfaces 32 of the support ribs 30; in particular, the first support surfaces 32 rest on the second support surfaces 40 to position the light source module 4 relative to the optical system 6 in the x-direction. The first and second support surfaces 32, 40 form the support geometry of the light module 2.

[0047] In this embodiment, the recesses 42 thus form both the second support surfaces 40 (bottom of the recesses 42) and the second stop surfaces 44 (front face of the recesses 42). Alternatively, the second support surfaces 40 and the second stop surfaces 44 can also be formed on separate parts or areas of the light source module 8 or the heat sink 8, respectively. For example, it would be conceivable that the second support surfaces 40 are formed directly on the side 38 of the support element 8 or the heat sink 20 facing the optical system 6.

[0048] Furthermore, the light module 4 comprises second stop surfaces 44 or 44a, 44b, extending parallel to the x-direction, on the side 38 of the support element 8 or the heat sink 20 facing the optical system 6. In the example shown, these are preferably formed by the front end faces of the recesses 42, which are located in the z-direction and point in the -z-direction. The second stop surfaces 44 interact with the first stop surfaces 34 of the projections 36; in particular, the first stop surfaces 34 bear against the second stop surfaces 44 to position the light source module 4 relative to the optical system 6 in the yz-plane perpendicular to the x-direction.

[0049] The recesses 42 for the reference surfaces 40, 44 can be very easily formed in the counterpart, in particular in the support element 8 or the heat sink 20. They can, in particular, be designed as embossed grooves. The recesses 42 are preferably formed on the side 38 of the support element 8 or the heat sink 20 facing the optical system 6. The side 38 can form a flat surface.

[0050] At least one of the second stop surfaces 44 is preferably shaped in the yz-plane such that, together with the corresponding counter-geometry on the reflector 14 (first stop surface 34), it fixes both components 4, 6 without play in two spatial directions y and z (see second stop surface 44a in Fig. 10) In particular, at least one of the second stop surfaces 44, viewed in the yz-plane, is arc-shaped, especially circular arc-shaped, or wedge-shaped. For the other second stop surface 44 (see second stop surface 44b in Fig. 9) It is sufficient if this forms only one stop, preferably a flat or planar stop, in one spatial direction, in particular in the z-direction.

[0051] Of course, the geometries for ensuring highly accurate positioning of the light source module 4 and the optical system 6 relative to each other can also be designed in any other way than shown in the figures and described here. The crucial point is that the geometries enable highly accurate positioning of the light source module 4 and the optical system 6 relative to each other in all three spatial directions x, y, z.

[0052] Thus, when both components 4 and 6 are in contact via the defined geometries 32 and 40 and 34 and 44, respectively, they are uniquely defined in all spatial directions x, y, z and positioned relative to each other without any play; that is, the desired relative position is achieved. The optical system 6 is then attached to the light source module 4 in the achieved relative position. For this purpose, the present invention proposes a particularly reliable, safer, durable, cost-effective, and easy-to-use fastening system.

[0053] The invention particularly proposes the use of a spring element 50 which, after reaching the relative position for attaching the light source module 4 and the optical system 6 to each other, acts between them in such a way that it keeps both the support surfaces 32, 40 of the support geometry and the stop surfaces 34, 44 of the stop geometry in contact with each other for the duration of the spring action.

[0054] In the examples shown here, the spring element 50 is designed as a bow spring 52. Of course, the spring element 50 can also be designed in any other way, e.g., as a leaf spring. The crucial point is that a single spring element 50 is able to act between the light source module 4 and the optical system 6 in such a way that it keeps both the contact surfaces 32, 40 of the support geometry (positioning in the x-direction) and the stop surfaces 34, 44 of the stop geometry (positioning in the yz-plane) in contact with each other for the duration of the spring action.

[0055] The spring 52 is rotatably suspended from the light source module 4 or the optical system 6. In the example shown, the spring 52 is suspended from the light source module 4, in particular from the support element 8 or heat sink 20, by two opposing bearing ends 53.

[0056] An active section 54 of the spring 52 then acts on the other component of the light module 2, to which the spring 52 is not attached, and presses the two components 4, 6 against each other by means of the spring action. In the example shown, the active section 54 interacts with the optical system 6 or the reflector 14. Preferably, the active section 54 interacts directly with the optical system 6 or the reflector 14, or with a component formed integrally with it. The spring 52 can be tensioned automatically during the positioning process (light source module 4 and optical system 6 relative to each other until the relative position of the two components 4, 6 is reached) of the assembly process, as shown in the figures. Alternatively, although not part of the present invention, it would also be conceivable for the spring 52 to be manually pivoted into a final assembly position, e.g.by a user or a service employee, which then tensions it until it reaches the final assembly position.

[0057] A rib-shaped geometry 56 is formed on the rear side of the reflector 14. Preferably, one rib 56 is arranged along a vertical center plane of the light module 2. Of course, several ribs 56, e.g., two, can also be provided spaced apart from the vertical center plane. The geometry 56 is formed integrally with the reflector 14. The rib 56 is preferably connected to the rear side of the reflector as well as to a top surface of the mounting base 28 of the reflector 14. Naturally, the geometry 56 could also be formed in any other way and at any other location within the optical system 6.

[0058] The geometry 56 can provide a snap-in geometry 58, which can be designed, for example, as a recess or indentation on an edge of the rib. The bracket spring 52 can be in its final assembly position (see figure). Fig. 1 and Fig. 7) engage in the locking geometry 58. In particular, the spring element 50 is designed to engage in the locking geometry 58 for the duration of the spring action, which presses the light source module 4 and the optical system 6 against each other. The locking geometry 58 is designed to prevent the spring element 50 from disengaging and moving out of its final mounting position, even in the event of vehicle vibrations or impacts. To release the spring element 50, the working section 54 of the spring element 50 is manually lifted so that it disengages from the locking geometry 58. Consequently, the front end of the light source module 4, pointing in the z-direction, can be lifted off the optical system 6 (tilted about the y-axis in the -x direction) and moved away from the optical system 6 in the opposite direction to a mounting or joining direction 62.

[0059] Furthermore, the optical system 6 or the reflector 14 can be provided with a ramp 60. This allows the spring element 50 or the spring clip 52 to tension itself automatically during the positioning process. This will be shown below using the Fig. 5 to 7 explained in more detail.

[0060] The mounting of the light module 2 or the optical system 6 of the light module 2 on the light source module 4 of the light module 2 is carried out, for example, as follows: The procedure begins in a functional block 70 (see Fig. 12). In a functional block 72, the light source module 4 and the optical system 6 are provided and brought close together in preparation for the assembly process, e.g. by moving the light source module 4 in a joining or assembly direction 62 towards the optical system 6 or the reflector 14 (see Fig. 5) The support geometries 32 on the optical system 6 or the reflector 14, which engage in the respective recesses 42 on the support element 8 or heat sink 20, can serve as positioning or joining aids. To begin the actual assembly process, the spring element 50 or the band spring 52 with its effective section 54 is brought into contact with an initial position 64 on the ramp 60 in a functional block 74 (see Figure 5). Fig. 6) During the assembly process, the light source module 4 is moved further towards the optical system 6 in a functional block 76 in the joining direction 62, whereby the effective section 54 of the spring element 50 or the spring clip 52 slides along the ramp 60 of the optical system 6 or the reflector 14. This causes the spring element 50 to move in the direction of the locking geometry 58, and the spring element 50 is automatically tensioned. In the final assembly position, i.e., at the end of the assembly process or at the end of the positioning of the light source module 4 and the optical system 6 relative to each other in the relative position, the spring element 50 automatically locks into the locking geometry 58 (see Figure 5). Fig. 7) and henceforth exerts its spring action. This corresponds to the functional block 78. Almost simultaneously, the optical system 6 or the reflector 14 with its stop geometry 34 snaps into the recesses 42 on the support element 8 or the heat sink 20.

[0061] The spring force F_V of the spring element 50 in the assembly end position (see Fig. 7) acts obliquely on the optical system 6 or on the geometry 56, which is formed integrally with the optical system 6. In particular, the spring force F_V has a stop force component F_An in the z-direction and a support force component F_Auf in the x-direction (see Fig.8) Due to the oblique force direction of the tensioned spring element 50, the two components 4, 6 are then firmly and precisely connected to each other at the designated reference geometries (support geometry 32 and stop geometry 34) without play. The direction of action of the spring force F_V is designed such that component contact is permanently ensured at all reference geometries 32, 34 by a continuously acting spring tension. During the duration of the spring action, contact between the support surfaces 32, 40 is maintained by the support force component F_Auf, and contact between the stop surfaces 34, 44 is maintained by the stop force component F_An.

[0062] The spring element 50 can either be automatically tensioned – as described – during the assembly process of both components 4 and 6, or it can be manually folded into the final assembly position. During the pivoting movement, it is then manually tensioned until it engages with the corresponding locking geometry 58 on the optical system 6.

[0063] The present invention provides a permanent, secure, robust, and precisely positioned connection between the light source module 4 and the optical system 6 (or an optically active component). The connection is detachable, allowing the light source module 4 to be replaced with the semiconductor light source 10 even when the vehicle lighting unit 100 is installed, for example, during servicing. This, however, requires a sufficiently large maintenance opening on the housing 104 of the lighting unit 100 and good accessibility of the maintenance opening within the vehicle. Thanks to the use of the spring element 50, the light source module 4 can be mounted or dismounted without additional aids, such as special tools. The invention enables simple, quick, and cost-effective installation, as the light source module 4 can be precisely snapped into position on the optical system 6.

[0064] With the invention, the interface necessary for attaching the light source module 4 to the optical system 6 can be produced very simply and therefore cost-effectively, since a slide-less reflector tool can be used because no screw dome needs to be demolded.

Claims

[1] Light module (2) of a motor vehicle lighting device (100), comprising a light source module (4) with a semiconductor light source (10) mounted on a support element (8) for emitting light (48) and an optical system (6) for deflecting and / or shaping the emitted light (48), wherein the light source module (4) and the optical system (6) are positioned relative to each other in three-dimensional space (x, y, z) by means of a stop and support geometry and then attached to each other, wherein the light module (2) is designed such that, after positioning the light source module (4) and the optical system (6) relative to each other in three-dimensional space (x, y, z), a spring element (50, 52) acts between them to fasten the light source module (4) and the optical system (6) to each other, wherein the spring element (50, 52) is designed to keep the bearing surfaces (32, 40) of the bearing geometry and the stop surfaces (34, 44) of the stop geometry in contact with each other for the duration of the spring action, and the light module (2) is designed such that the spring element (50, 52) acts directly between the light source module (4) and the optical system (6) or a component (56) formed integrally with it, wherein the spring element (50, 52) is rotatably suspended on the light source module (4), in particular on the support element (8) of the light source module (4), or on the optical system (6), wherein the spring element (50, 52) is arranged and designed in the light module (2) such that at the end of the positioning of the light source module (4) and the optical system (6) relative to each other it automatically snaps into a snap-in geometry (58) of the light source module (4) or of the optical system (6), wherein a ramp (60) is formed on the light source module (4) or the optical system (6) to which the spring element (50, 52) is non-rotatably suspended, which extends from an initial position (64) where the spring element (50, 52) rests relative to each other at the beginning of the positioning of the light source module (4) and the optical system (6) to the locking geometry (58), and the ramp (60) is designed such that the spring element (50, 52) slides along the ramp (60) during the positioning of the light source module (4) and the optical system (6) relative to each other, in order to then automatically lock into the locking geometry (58) at the end of the positioning of the light source module (4) and the optical system (6) relative to each other, and wherein the spring element (50, 52) is designed with a spring force (F_V) between the light source module (4) and the optical system (6)which has a supporting force component (F_Auf) in a first direction (x) and a striking force component (F_An) in a second direction (z) perpendicular to the first direction (x). [2] Light module (2) according to claim 1, characterized by , that the spring element (50) is designed as a bow spring (52). [3] Light module (2) according to claim 1 or 2, characterized by , that the locking geometry (58) is formed on the light source module (4) or the optical system (6) on which the spring element (50, 52) is non-rotatably suspended, and the spring element (50, 52) is designed to lock into the locking geometry (58) for the duration of the spring action. [4] Motor vehicle lighting device (100), in particular in the form of a motor vehicle headlight, comprising a housing (104) in which at least one light module (2) for generating and emitting light is arranged, characterized bythat the at least one light module (2) is designed according to one of the preceding claims. [5] Method for mounting an optical system (6) of a light module (2) according to claim 1 of a motor vehicle lighting device (100) according to claim 4 on a light source module (4) of the light module (2), comprising the following method steps: - Positioning the light source module (4) and the optical system (6) relative to each other in three-dimensional space (x, y, z) by means of a stop and support geometry formed on the light source module (4) and the optical system (6), and - Attaching the light source module (4) and the optical system (6) to each other after positioning the light source module (4) and the optical system (6) relative to each other in three-dimensional space (x, y, z), wherein the fastening of the light source module (4) and the optical system (6) to each other comprises a step (78) in which a spring element (50, 52) is activated, which keeps the support surfaces (32, 40) of the support geometry and the stop surfaces (34, 44) of the stop geometry in contact with each other for the duration of the spring action, and the spring element (50, 52) is brought into effect directly between the light source module (4) and the optical system (6) or a component (56) formed integrally with it, the spring element (50, 52) is rotatably suspended on the light source module (4), in particular on the support element (8) of the light source module (4), or on the optical system (6), the spring element (50, 52) automatically engages in a snap-in geometry (58) of the light source module (4) or the optical system (6) at the end of the positioning of the light source module (4) and the optical system (6) relative to each other, a ramp (60) formed on the light source module (4) or the optical system (6) on which the spring element (50, 52) is non-rotatably suspended, extends from an initial position (64) where the spring element (50, 52) rests relative to each other at the beginning of the positioning of the light source module (4) and the optical system (6), to the locking geometry (58), and the ramp (60) is designed such that the spring element (50, 52) slides along the ramp (60) during the positioning of the light source module (4) and the optical system (6) relative to each other, in order to then automatically lock into the locking geometry (58) at the end of the positioning of the light source module (4) and the optical system (6) relative to each other, and the spring element (50, 52) acts for the duration of the spring action with a spring force (F_V) between the light source module (4) and the optical system (6), which has a support force component (F_Auf) in a first direction (x) and a stop force component (F_An) in a second direction (z) perpendicular to the first direction (x).

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