Multifunctional projection module for a motor vehicle headlight

Abstract

The invention relates to a multi-function projection module (10) for a motor vehicle headlight, comprising a first light source arrangement (12) to which a first primary optics (14) and a diaphragm arrangement (22) with a diaphragm edge (26) for generating a light-dark boundary are assigned, and comprising a second light source arrangement (56) to which a second primary optics (58) is assigned, and a projection lens (28), wherein the multi-function projection module (10) is designed toto generate a first light function, light from the first light source arrangement (12) is imaged via the first primary optics (14) by means of the projection lens (28) in the form of a first light distribution (40) in a front area of the multi-function projection module (10); and to generate a second light function, light from the second light source arrangement (56) is imaged via the second primary optics (58) by means of the projection lens (28) in the form of a second light distribution in the front area of the multi-function projection module (10). It is proposed that an intermediate optics (30) be arranged in a beam path between the diaphragm arrangement (22) and the projection lens (28), wherein the intermediate optics (30) is arranged and designed such that light (34) emerging from at least one horizontal edge region (32, 32') of the first primary optics (14) is deflected onto the projection lens (28) and imaged by the projection lens (28) in such a way thatthat this light illuminates at least one horizontal edge region of the first light distribution (40).,

Description

[0001] The present invention relates to a multi-function projection module for a motor vehicle headlight according to the preamble of claim 1 and a motor vehicle headlight with such a multi-function projection module.

[0002] A multifunction projection module is a projection module that allows switching between different lighting functions. Examples of such lighting functions include low beam functions and high beam functions.

[0003] The multi-function projection module in question comprises a first light source arrangement, to which a first primary optics and a diaphragm arrangement with a diaphragm edge for generating a cut-off line are assigned, and a projection lens. To generate a first light function, for example, a low-beam function, light from the first light source arrangement is projected via the first primary optics by means of the projection lens in the form of a first light distribution in a front area of the projection module.

[0004] The multi-function projection module in question further comprises a second light source arrangement, to which a second primary optics is assigned. To generate a second light function, for example, a high beam function, light from the second light source arrangement is projected via the second primary optics by means of the projection lens in the form of a second light distribution in the area in front of the projection module. State of the art

[0005] Multifunctional projection modules are known from the state of the art.

[0006] In order to design projection modules that save as much space and material as possible, projection modules that do not require an aperture arrangement are known from the state of the art. Reducing the size of the module generally also reduces the width of the light source. Furthermore, the module's overall length is also reduced, positioning the light source, which is now smaller in width, closer to an object plane of the projection optics. This reduces the illuminated object size both vertically and horizontally. This is generally accompanied by a reduction in the illumination in front of the module and a reduction in the lateral illumination.

[0007] US10337684 discloses an arrangement with a one-piece lens attachment. This lens attachment is associated with both the light sources used to generate a low beam function and the light sources used to generate a high beam function. To achieve the widest possible light distribution, the edge areas of the lens attachment are specially designed.

[0008] WO 2021 / 244735 and WO 2021 / 244736 also describe such a one-piece optical element for an attachment lens, which combines entrance surfaces, light guides, and exit surfaces with the properties of a collimator. Furthermore, the lower high-beam area is tilted toward the upper low-beam area to improve the overlap between the low-beam and high-beam beams. The cut-off line inside the component is defined by the intersection of the low-beam and high-beam light guides.

[0009] In addition, WO 2021 / 244736 describes additionally enlarged entrance surfaces for an auxiliary lens. This should enable the use of multiple LEDs as light sources, thereby increasing the lateral illumination from the standard + / -30° (cf., for example, WO 2017 / 198516) to + / -40°. However, this monolithic component of the primary lens, with the advantages of a single-piece design, is characterized by relatively high wall thicknesses, i.e., material thicknesses, which results in a relatively high material requirement and thus higher costs, increased space requirements, and extended production times.

[0010] Against this background, the object of the invention is to provide a multi-function projection module of the type mentioned at the outset, which is designed to be as space- and material-saving as possible, while at the same time ensuring a high efficiency of the module. Disclosure of the invention

[0011] This object is achieved with a multi-function projection module having the features of claim 1.

[0012] In such a multi-function projection module, it is provided that an intermediate optic is arranged in a beam path between the diaphragm arrangement and the projection lens, wherein the intermediate optic is arranged and designed such that light emerging from at least one horizontal edge region of the first primary optic is deflected onto the projection lens and is imaged by the projection lens such that this light illuminates at least one horizontal edge region of the first light distribution.

[0013] By introducing the intermediate optics, the horizontal illumination area of the first light distribution can be increased without having to increase the size of the multifunction projection module. To broaden the first light distribution in horizontal edge regions, the intermediate optics ensures that the light emerging from the horizontal edge regions of the first primary optics falls onto the projection optics at a relatively steep angle and can thus be used efficiently to illuminate the horizontal edge regions of the first light distribution. The light emerging from the horizontal edge regions of the first primary optics is largely emitted by light sources of the first light source arrangement located horizontally at the edge.

[0014] By using the intermediate optics, a horizontal broadening of the first light distribution can be achieved, which without the intermediate optics can only be achieved by enlarging the first primary optics and / or the projection lens and by increasing the distance between the first primary optics and the projection lens. The horizontal broadening of the first light distribution can be achieved by the intermediate optics according to the invention without having to increase the material thickness of the first primary optics and / or the projection lens. This allows the material requirements of the multifunctional projection module as a whole to be reduced and cycle times for the production of the optical elements, such as the first primary optics and / or the projection lens, to be minimized.

[0015] Furthermore, when appropriately positioned in the beam path between the aperture arrangement and the projection lens, the intermediate optics offer the opportunity to increase lateral illumination and improve the homogeneity of the light distribution despite the compactness of the arrangement. By placing the intermediate optics between the projection lens and an edge of the aperture arrangement to be imaged, a virtually larger image of the light distribution in the object plane can be generated, which is equivalent to an apparently wider light source arrangement, making a wider light distribution possible even in a compact installation space. By using the intermediate optics between the object plane and the projection lens, a horizontally and vertically enlarged virtual image can be generated in the object plane, thus compensating for or expanding the foreground and lateral illumination despite a smaller installation space.

[0016] The use of the aperture arrangement improves the scattered light behavior and / or glare behavior of the multi-function projection module, because the strict separation of areas of the first and second light function, in particular the low beam and high beam functions, significantly reduces or eliminates crosstalk between the two areas and thus has a positive effect on glare behavior.

[0017] In a monolithic approach without a diaphragm arrangement, for example, when a single primary optic is used for both lighting functions, preventing crosstalk is not easily possible. Foregoing the use of a diaphragm arrangement, especially a mirror diaphragm arrangement, also results in the projection modules known from the prior art making it difficult to achieve high intensities in the light distribution at the cut-off line. Furthermore, omitting the use of a diaphragm arrangement can negatively impact thermal behavior and thus the stability of the cut-off line, and in particular its color fringe.

[0018] The aperture arrangement can, in particular, be designed as a mirror aperture arrangement. This can increase the efficiency of the arrangement, since both indirect light, i.e. light reflected by the mirror aperture arrangement, and directly emitted light are combined to form the first light distribution.

[0019] The projection lens can, for example, be designed as a bi-convex lens. This can reduce losses due to total internal reflection within the imaging projection lens.

[0020] According to one embodiment, it is provided that the intermediate optics is designed in the form of a lens, in particular at least partially as a convex lens.

[0021] It can be provided that a convex curvature is provided on a front side of the intermediate optics in at least one horizontal edge region of the intermediate optics. The light emerging from the horizontal edge region of the first primary optics strikes the horizontal edge region of the intermediate optics and is redirected by the horizontal edge region of the intermediate optics onto the projection lens.

[0022] For example, a convex curvature is provided in both horizontal edge regions of the intermediate optic. It can be provided that the two horizontal edge regions of the intermediate optic with the convex curvatures are horizontally connected by a central region of the intermediate optic. In the central region, the intermediate optic comprises, for example, a flat surface or a concave curvature on the front side. Thus, the two horizontal edge regions are connected via the central region to form a continuous exit surface of the intermediate optic.

[0023] It can advantageously be provided that a front side and / or a rear side of the intermediate optics comprises an optically effective structure, in particular a prism- or wave-shaped structure. Such a structure can be advantageous for homogenizing the first light distribution. The homogenization can be further enhanced or influenced only locally if an additional graining and / or fine graining is incorporated into the surfaces of the front side and / or rear side of the intermediate optics over a large area and / or even only locally.

[0024] The intermediate optics can, in principle, be made of any transparent material. It can advantageously be provided that the intermediate optics is made of or comprises a material including polycarbonate or PMMA, polymethyl methacrylate, or silicone. PMMA or silicone, in particular, are comparatively thermally stable.

[0025] The light emerging from the edge region of the first primary optics and redirected to the projection lens by the intermediate optics illuminates, in the first light distribution, for example, a horizontal edge region between +35° and +55°, in particular between +40° and +50°, and / or a horizontal edge region between -35° and -55°, in particular between -40° and -50°. As a result, the width of the first light distribution, for example the low beam distribution, can comprise a horizontal width of, in particular, + / - 45° or more.

[0026] It may prove advantageous if the intermediate optics have a recess so that light emerging from the second primary optics propagates through the recess of the intermediate optics. The corresponding light rays from the second light source arrangement can pass through the intermediate optics unhindered or almost unhindered and without loss and be imaged by the projection lens.

[0027] The first and / or second light source arrangements comprise, for example, a plurality of light sources, for example LEDs. The light sources are arranged, for example, in a row, i.e., a line, in the first and / or second light source arrangement. A multi-row, i.e., multi-line, arrangement, in particular in a matrix-like manner, would also be conceivable. It may be advantageous if the first and / or second light source arrangements comprise a plurality of light sources, in particular individually and / or in groups, controllable. In this way, individually adaptable lighting functions, for example, a segmented high beam function and / or a segmented low beam function, can be provided.

[0028] It can be provided that the first primary optics and / or the second primary optics are designed as a light guide arrangement comprising a plurality of light entry tubes and a common light exit surface. A respective light entry tube is assigned, for example, to a respective light source of the respective light source arrangement.

[0029] In an alternative embodiment, the first primary optics and / or the second primary optics comprise a plurality of TIR attachment optics. Each TIR attachment optic is assigned, for example, to a respective light source of the respective light source arrangement.

[0030] By using comparable optical technology for the first and second primary optics, the multifunctional projection module can be designed in a compact manner. Combining this with, for example, a mirror aperture arrangement increases the proportion of usable indirectly emitted light, thus enhancing overall efficiency.

[0031] The first and / or second primary optics can generally be made of polycarbonate. The use of silicone can prove advantageous, particularly with regard to manufacturing, material thickness, and thermal robustness.

[0032] It may be advantageous for the first light source arrangement and the second light source arrangement to be arranged in a common plane. In this case, an arrangement on a common carrier, for example, a printed circuit board, in particular a circuit board, is also conceivable. This can be both cost-effective in production and space-saving in the arrangement.

[0033] The disclosure primarily describes a horizontal broadening of the light distribution. Analogously, it is also possible to expand / broaden the light distribution in the vertical direction.

[0034] Further embodiments relate to a motor vehicle headlight comprising a multi-function projection module according to the described embodiments.

[0035] Further advantages will become apparent from the description and the accompanying drawings. Exemplary embodiments of the invention are illustrated in the drawings and explained in more detail in the following description. Identical reference numerals in different figures designate identical or at least functionally comparable elements. When describing individual figures, reference may also be made to elements from other figures. These show, in schematic form: Fig. 1 shows a schematic representation of a multi-function projection module according to the invention according to a first embodiment in a perspective view; Fig. 2 a schematic representation of the multi-function projection module according to the invention from Fig. 1 in a top view; Fig. 3 a schematic representation of a multi-function projection module not according to the invention; Fig. 4 a schematic representation of a light distribution that can be generated with a multi-function projection module according to the invention according to a first function of the multi-function projection module; Fig. 5 a schematic representation of a section of the multi-function projection module according to the invention from Fig. 1 in a perspective view from the front; Fig. 6 a schematic representation of the multi-function projection module according to the invention from Fig. 1 in a perspective view according to a second function of the multi-function projection module; Fig. 7 shows a schematic representation of a multi-function projection module according to the invention according to a second embodiment in a perspective view; Fig. 8 a schematic representation of the multi-function projection module according to the invention from Fig. 7 in a side view.

[0036] The Fig. 1, Fig. 2, Fig. 5 and Fig. 6 show a schematic representation of a multi-function projection module according to the invention according to a first embodiment in various views. The multi-function projection module, hereinafter also referred to as the projection module, is designated in its entirety by the reference numeral 10.

[0037] The Fig. 7 and Fig. 8 show a schematic representation of a multi-function projection module according to the invention according to a second embodiment in different views.

[0038] The projection module 10 comprises a first light source arrangement 12, not shown in detail. In the example, the first light source arrangement 12 comprises an arrangement of ten individual light sources arranged in series.

[0039] A first primary optics system 14 is assigned to the first light source arrangement 12. In the example, the first primary optics system 14 comprises a light guide arrangement comprising ten light entry tubes 16 and a common light exit surface 18. Each light entry tube 16 is assigned to a respective light source of the first light source arrangement 12. Light emitted by the light sources of the first light source arrangement 12 enters the first primary optics system 14 via light entry surfaces 20 of the light entry tubes 16 and exits again via the light exit surface 18. The first primary optics system 14 focuses the light emitted by the light sources of the first light source arrangement 12.

[0040] The projection module 10 comprises a diaphragm arrangement 22, for example, a mirror diaphragm arrangement. A top side 24 of the diaphragm arrangement 22 comprises, for example, a reflective surface. The diaphragm arrangement 22 comprises a diaphragm edge 26 for generating a cut-off line in a first light distribution, which is generated with light emitted by the first light source arrangement 12. The first light distribution is, for example, a low-beam distribution, see also Fig. 4. The aperture edge 26 of the aperture arrangement 22 defines the shape of the cut-off line of the imaged light distribution.

[0041] The projection module 10 comprises a projection lens 28. A first light function of the projection module 10 is imaged with light emitted by the first light source arrangement 12, which is bundled by the first primary optics 14, by means of the projection lens 28 in the form of a first light distribution in a front area of the projection module 10. The projection lens 28 is designed in the example as a plano-convex lens, cf. Fig. 1, Fig. 7 and Fig. 8, or as a biconvex lens, cf. Fig. 2 and Fig. 6. Other lens shapes are also conceivable.

[0042] The projection module 10 comprises an intermediate optics 30. The intermediate optics 30 are arranged in a beam path between the aperture arrangement 22 and the projection lens 28. The intermediate optics 30 are arranged and designed such that light emerging from at least one horizontal edge region 32 of the first primary optics 14 is deflected onto the projection lens 28. This is shown, for example, in Fig. 2 shown. Fig. 2 schematically shows a beam of rays 34 emerging from the horizontal edge region 32 and being deflected in a horizontal edge region 36 of the intermediate optics 30 such that the light beam 38 falls onto the projection lens 28. The projection lens 28 images the light beam 38 such that this light illuminates a horizontal edge region of the first light distribution.

[0043] Fig. 3 shows a part of a projection module without such an intermediate optic 30. In Fig. 3 shows that a portion 34' of the beam 34 passes the projection lens 28. This portion cannot then be received and imaged by the projection lens 28. This reduces the efficiency of the projection module. Without the intermediate optics 30, only a small portion of the beam 34 emerging from the horizontal edge region 32 of the first primary optics 14 would be imaged by the projection lens 28 into the horizontal edge region of the first light distribution.

[0044] Fig. 4 shows an example of a first light distribution 40 that can be generated on a measuring screen arranged at a distance (e.g. 25 m) in front of the motor vehicle or in front of the projection module 10. In the illustration, a horizontal axis HO and a vertical axis V are plotted, which intersect at a point (0°, 0°).

[0045] The first light distribution 40 in the example is a low beam distribution with a cut-off line 42. In the example, the low beam distribution covers a horizontal extent of -50° to +50°.

[0046] The beam 34, which emerges from the horizontal edge region 32 of the primary optics and is deflected onto the projection lens 28 in the horizontal edge region 36 of the intermediate optics 30, illuminates a horizontal edge region of the first light distribution. The horizontal edge region of the first light distribution extends from approximately -50° to -40°, in particular from -50° to -45°.

[0047] A beam of rays (in Fig. 2 not shown), which emerges from the horizontal edge region 32' of the primary optics and is deflected onto the projection lens 28 in the horizontal edge region 36' of the intermediate optics 30, also illuminates a horizontal edge region of the first light distribution. This horizontal edge region of the first light distribution extends from approximately +40° to +50°, in particular from +45° to +50°.

[0048] In the example, a convex curvature is provided on a front side 46 of the intermediate optics 30 in the horizontal edge regions 36, 36' of the intermediate optics 30. The two horizontal edge regions 36, 36' of the intermediate optics 30 with the convex curvatures are connected horizontally by a central region 48 of the intermediate optics 30. In the example, the intermediate optics includes a concave curvature in the central region 48 on the front side 46. Alternatively, a flat surface could also be provided. The two horizontal edge regions 36, 36' are connected via the central region 48 to form a continuous exit surface 50 of the intermediate optics 30.

[0049] It can advantageously be provided that the front side 46 and / or a rear side 52 of the intermediate optics comprises an optically effective structure, in particular a prism- or wave-shaped structure (not shown in the figures). Such a structure can be advantageous for homogenizing the first light distribution. The homogenization can be further enhanced or influenced only locally if an additional graining and / or fine granulation is additionally incorporated into the surfaces of the front side 46 and / or rear side 52 of the intermediate optics over a large area and / or only locally.

[0050] The intermediate optics 30 can, in principle, be formed from any transparent material. It can advantageously be provided that the intermediate optics is formed from or comprises a material comprising polycarbonate or PMMA, polymethyl methacrylate, or silicone. PMMA or silicone, in particular, are comparatively thermally stable.

[0051] In the example, the intermediate optics 30 comprises a recess 54. The function of the recess 54 will be explained further in connection with a second light source arrangement 56 of the projection module 10.

[0052] The projection module 10 comprises a second light source arrangement 56 (not shown in detail) for generating a second light function. In the example, the second light source arrangement 56 comprises an arrangement of nine individual light sources arranged in series.

[0053] A second primary optics unit 58 is assigned to the second light source arrangement 56. In the example, the second primary optics unit 58 is designed analogously to the first primary optics unit 14. Accordingly, the second primary optics unit 58 in the example comprises a light guide arrangement comprising nine light entry tubes 60 and a common light exit surface 62. Each light entry tube 60 is assigned to a respective light source of the second light source arrangement 56. Light emitted by the light sources of the second light source arrangement 56 enters the second primary optics unit 58 via light entry surfaces of the light entry tubes 60 and exits again via the light exit surface 62. The second primary optics unit 58 focuses the light emitted by the light sources of the second light source arrangement 56.

[0054] To generate the second light function, for example a high beam function, light from the second light source arrangement 56 is imaged via the second primary optics 58 by means of the projection lens 28 in the form of a second light distribution in the area in front of the projection module 10, cf. for example Fig. 6.

[0055] In the example, the light emerging from the second primary optics 58 is propagated through the recess 54 of the intermediate optics 30. The corresponding light rays from the second light source arrangement 56 can thus pass through the intermediate optics 30 unhindered, or almost unhindered, and without loss and be imaged by the projection lens 28. Accordingly, the intermediate optics 30 does not influence the second light function.

[0056] Alternatively, embodiments with an intermediate optic 30 without a recess (not further shown) are also conceivable.

[0057] In the example, the first and second light functions are separated by the aperture arrangement 22. The use of the aperture arrangement 22 improves the scattered light behavior and / or glare behavior of the projection module 10, because the strict separation of areas of the first and second light functions, in particular the low beam and high beam functions, significantly reduces or eliminates crosstalk between the two areas, thus favorably influencing the glare behavior.

[0058] It may be advantageous if the first and / or second light source arrangement 12, 56 comprises a plurality of controllable light sources, in particular individually and / or in groups. In this way, individually adaptable lighting functions, for example, a segmented high beam function and / or a segmented low beam function, can be provided.

[0059] The Fig. 7 and Fig.8 show a further embodiment of a multifunctional projection module 10 according to the invention. In the example, the first primary optics 14 comprises a number of ten TIR attachment optics 70. Each TIR attachment optics 70 is assigned, for example, to a respective light source of the first light source arrangement 12. Each TIR attachment optics 70 is made, for example, of silicone. By using silicone as the material, smaller minimum distances to the light sources of the first light source arrangement 12 can be realized, whereby the overall geometry of the primary optics 14 can be made smaller than if it were made of polycarbonate, for example. This provides an efficient alternative for the realization of a first primary optics 14 from light guide tubes.

[0060] It may be advantageous for the first light source arrangement 12 and the second light source arrangement 56 to be arranged in a common plane. In this case, arrangement on a common carrier (not shown), for example a printed circuit board, in particular a circuit board, is also possible. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 10337684

[0007] WO 2021 / 244735

[0008] WO 2021 / 244736 [0008, 0009] WO 2017 / 198516

[0009]

Claims

[1] A multi-function projection module (10) for a motor vehicle headlight, comprising a first light source arrangement (12) to which a first primary optics (14) and a diaphragm arrangement (22) with a diaphragm edge (26) for generating a light-dark boundary are assigned, and comprising a second light source arrangement (56) to which a second primary optics (58) is assigned, and a projection lens (28), wherein the multi-function projection module (10) is configured to image light from the first light source arrangement (12) via the first primary optics (14) by means of the projection lens (28) in the form of a first light distribution (40) in a front area of the multi-function projection module (10) in order to generate a first light function, and to image light from the second light source arrangement (56) via the second primary optics (58) by means of the projection lens (28) in the form of a second light distribution in the front area of the multi-function projection module (10) in order to generate a second light function,, characterized by that an intermediate optics (30) is arranged in a beam path between the diaphragm arrangement (22) and the projection lens (28), wherein the intermediate optics (30) is arranged and designed such that light (34) emerging from at least one horizontal edge region (32, 32') of the first primary optics (14) is deflected onto the projection lens (28) and is imaged by the projection lens (28) such that this light illuminates at least one horizontal edge region of the first light distribution (40). [2] Multifunctional projection module (10) according to claim 1, wherein the intermediate optics (30) is designed in the form of a lens, in particular at least partially as a convex lens. [3] Multifunctional projection module (10) according to one of claims 1 or 2, wherein a convex curvature is provided on a front side (46) of the intermediate optics (30) in at least one horizontal edge region of the intermediate optics (30). [4] Multifunctional projection module (10) according to one of the preceding claims, wherein a front side (46) and / or a rear side (52) of the intermediate optics (30) comprises an optically effective structure, in particular a prism-shaped or wave-shaped structure. [5] Multifunctional projection module (10) according to one of the preceding claims, wherein the intermediate optics (30) is formed from or comprises a material comprising polycarbonate or PMMA or silicone. [6] Multifunctional projection module (10) according to one of the preceding claims, wherein the light (34, 38) emerging from the edge region (32, 32') of the first primary optics (14) and deflected onto the projection lens by means of the intermediate optics (30) illuminates a horizontal edge region between +35° and +55°, in particular between +40° and +50° and / or a horizontal edge region between -35° and -55°, in particular between -40° and -50°, in the first light distribution (40). [7] Multifunctional projection module (10) according to one of the preceding claims, wherein the intermediate optics (30) has a recess (54) so that light emerging from the second primary optics (58) propagates through the recess (54) of the intermediate optics (30). [8] Multifunctional projection module (10) according to one of the preceding claims, wherein the second light source arrangement (56) comprises a plurality of light sources, in particular individually and / or in groups, which can be controlled. [9] Multifunctional projection module (10) according to one of the preceding claims, wherein the first primary optics (14) and / or the second primary optics (58) are each designed as a light guide arrangement comprising a plurality of light entry tubes (16, 60) and a respective common light exit surface (18, 62), and / or wherein the first primary optics (14) and / or the second primary optics (56) comprise a plurality of TIR attachment optics (70). [10] Multifunctional projection module (10) according to one of the preceding claims, wherein the first light source arrangement (12) and the second light source arrangement (56) are arranged in a common plane. [11] Motor vehicle headlight comprising a multi-function projection module (10) according to one of the preceding claims.

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