Headlight for a vehicle, method for producing a lens for a headlight and vehicle

Abstract

The invention relates to a headlight (12) for a vehicle (10), comprising at least one illuminant (14) for generating light beams, at least one radar (16) for generating radar beams, and at least one lens (18) designed as a radome (22), characterized in that a heating device (24) is integrated into the lens (18). Furthermore, the invention relates to a method for producing a lens (18) for such a headlight (12), and to a vehicle having at least one such headlight (12) and / or having at least one headlight (12) comprising a lens (18) produced using such a method.

Description

[0001] The present invention relates to a headlight for a vehicle, comprising at least one light source for generating light beams, at least one radar for generating radar beams, and at least one light lens designed as a radome. The invention further relates to a method for manufacturing a light lens for such a headlight, as well as to a vehicle with at least one such headlight and / or with at least one headlight comprising a light lens manufactured by such a method.

[0002] Modern vehicles utilize a wide variety of external sensors. When integrating these sensors into the vehicle, their design, technology, and protection must always be considered. To achieve a flush design on the vehicle's front, it is common practice to integrate sensors, such as radar sensors for measuring the distance to an object, within the headlight. This necessitates that the headlight lens function like a radome, making it essential to keep the lens free of snow.

[0003] From DE 10 2017 131 441 A1, a headlight for a vehicle is known, comprising a housing with an opening, at least one light source arranged in at least one light module in front of the headlight to generate a predetermined light distribution, and a cover plate device that closes the opening and allows visible light from the light source to pass through. For defrosting the cover plate, a defrosting device is provided with a radiation emitter arranged inside the headlight housing but outside the at least one light module, and a radiation coupling device. Radiation generated by the radiation emitter can be fed into the cover plate by the radiation coupling device, whereby the radiation is guided reflectively along an outer surface of the cover plate within the cover plate.

[0004] From DE 100 26 454 C1, a radome for a distance warning radar in a motor vehicle is known, on which the formation of snow or ice layers is prevented. For this purpose, the radome has thin, radar-transparent metal layers for visual adaptation of the radome to its surrounding vehicle surface, wherein the thin metal layers have an ohmic resistance. An electric current is impressed into the metal layer by means of an electric current source to heat the radome, flowing laterally through the metal layers. Adjustable electrical resistors are provided in the electrical circuit for current supply, with which manufacturing-related differences in the ohmic resistance of the metal layers are compensated.

[0005] Furthermore, DE 10 2022 107 861 A1 discloses a cleaning control system for a vehicle radome and a method for operating a cleaning device of the cleaning control system for cleaning and / or de-icing a radome of a vehicle radar sensor. The method receives environmental data describing the vehicle's surroundings and / or at least a region of the vehicle's radome. Based on this environmental data, a precipitation deposit is detected, and depending on the detected precipitation deposit, a cleaning signal is output to the cleaning device for cleaning and / or de-icing the radome. The environmental data is received as image data from at least one camera of the vehicle, whereby precipitation in the surroundings and / or on the radome region is detected based on the image data.

[0006] The present invention is based on the objective of providing a headlight and a vehicle that enable the de-icing of a lens designed as a radome. Furthermore, the invention is based on the objective of providing a method for manufacturing a lens for a vehicle that allows for the simple and cost-effective integration of a heating element into the lens.

[0007] To solve the problems, a headlight with the features of claim 1, a method with the features of claim 9 and a vehicle with the features of claim 10 are proposed.

[0008] Advantageous designs of the headlight are the subject of the dependent claims.

[0009] According to a first aspect of the invention, a headlight for a vehicle is proposed which has at least one light source for generating light beams, at least one radar for generating radar beams and at least one light disc designed as a radome, wherein a heating device is integrated into the light disc.

[0010] The integrated heating element allows the radome-shaped lens to be heated, thus keeping it free of snow and ice. Furthermore, the integrated heating element results in a simple and cost-effective design for the headlight.

[0011] The light source can contain one or more light-emitting diodes (LEDs) and / or laser diodes. LEDs and / or laser diodes offer high brightness combined with low energy consumption and therefore high energy efficiency.

[0012] The radome serves as protection for the radar. Advantageously, the radome is designed to be transparent, allowing the radar beams to pass through it.

[0013] In an advantageous embodiment, the headlight has a housing in which the light source and the radar are arranged. To protect the light source and the radar, the housing is enclosed by the light lens, which is designed as a radome.

[0014] In an advantageous embodiment, the heating device comprises a control unit, a power source connected to the heating device, and a temperature sensor. The temperature sensor measures a temperature and transmits this value to the control unit. If the control unit detects that the measured temperature corresponds to or is below a predetermined temperature limit, it activates the power source, which then supplies current to the heating device. This causes the heating device to switch on automatically. Advantageously, the heating device switches on at 5°C or below.

[0015] In an advantageous embodiment, the lens comprises a first layer of transparent plastic, a second layer of transparent plastic, and a film arranged between the two layers, with the heating element applied to the film. Since the layers are made of transparent plastic, they are permeable to radar waves. Advantageously, the film is also made of transparent plastic. By embedding the heating element between two transparent plastic layers, it is protected from environmental influences such as stone chips, dirt, and / or water. The heating element is preferably bonded to the film. The layers are advantageously bonded together by a material-bonded structure. This allows the transparent plastic to be injection-molded onto both sides of the film to form the layers.Furthermore, it is advantageous that the first layer is arranged facing outwards, i.e. away from the light source and the radar, and the second layer is arranged on the inside, i.e. towards the light source and the radar.

[0016] In an advantageous embodiment, the heating element is bonded to the film. This allows for a strong connection between the heating element and the film. The heating element can be glued and / or welded to the film, for example, by ultrasonic welding.

[0017] In an advantageous embodiment, the heating device comprises a heating wire. By supplying electricity to the heating wire, it is heated, thus removing ice and / or snow from the lens. Advantageously, the heating wire is integrated into the lens in a meandering shape.

[0018] In an advantageous embodiment, the first layer has a thickness between 1 mm and 5 mm, in particular a thickness of 3.5 mm, the second layer has a thickness between 1 mm and 5 mm, in particular a thickness of 2.8 mm, and the film has a thickness between 0.2 mm and 0.8 mm, in particular a thickness of 0.5 mm. This results in a stable yet lightweight structure for the light panel.

[0019] In an advantageous embodiment, a black print is applied to the film. The inclusion of a black print serves as a design element. This allows a contour, particularly a delicate contour, to be created on the light lens.

[0020] In a preferred embodiment, a coating is applied to one of the layers. This coating can be a hard coating that protects the outer layer, made of a transparent plastic, from stone chips. For example, the coating can be a clear coat. It is advantageous to apply the coating to the first layer.

[0021] In an advantageous embodiment, the transparent plastic of the two layers and / or the film is made of a thermoplastic material. For example, the two layers and / or the film can be made of polycarbonate (PC).

[0022] According to a further aspect, a method for manufacturing a lens, in particular a lens shaped like a radome, for a headlight according to the invention is proposed. In the method, a heating wire is applied to a film in a first step. In a second step, the film together with the heating wire is placed in a forming tool, and the forming tool is closed. In a third step, a first layer of a transparent plastic and a second layer of a transparent plastic are injection-molded onto the film, so that the film and the heating wire are arranged between the two layers. In a fourth step, the forming tool is opened and the lens is removed. Advantageously, in a fifth step, the clear lacquer layer is applied to the first layer, for example, by spraying.

[0023] In an advantageous embodiment, the heating wire is applied to the film by bonding it to the film. For this purpose, the heating wire can be glued to the film or welded on, for example, by ultrasonic welding. Advantageously, the heating wire is applied to the film in a meandering pattern.

[0024] Advantageously, the film melts when the transparent plastic is injected, so that the film bonds with the transparent plastic in a material-bonded manner.

[0025] The film is advantageous if it is made of a thermoplastic material, especially one based on polycarbonate (PC).

[0026] In an advantageous embodiment, a black print is applied to the foil before the heating wire is applied.

[0027] In an advantageous embodiment, a vehicle with at least one headlight according to the invention and / or with at least one headlight comprising a lens is proposed to be manufactured using a method according to the invention.

[0028] The following section describes in more detail a vehicle, a headlight, a method for manufacturing a lens for the headlight, and other features and advantages using an exemplary embodiment, which is schematically illustrated in the figures. The figures show: Fig. 1 a vehicle with a headlight; Fig. 2. an enlarged view of the headlight; and Fig. 3 a cross-section through a light lens of the headlight along line III-III in Fig. 2.

[0029] In Fig. Figure 1 shows a vehicle 10 which has a drive machine designed as an internal combustion engine and / or electric motor.

[0030] Vehicle 10 has headlights 12, one of which is in Fig. 2 is shown enlarged.

[0031] The headlight 12 comprises a housing 13, at least one schematically depicted light source 14 for generating light beams, at least one schematically depicted radar 16 for generating radar beams, and at least one light lens 18. The light source 14 and the radar 16 are arranged in the housing 13, which is closed by the light lens 18.

[0032] The light source 14 can be a light-emitting diode (LED) and / or a laser diode. Light beams are emitted from the light source 14, which emerge from the headlight 12 through the lens 18 and illuminate, for example, a roadway.

[0033] The radar 16 emits 10 radar beams to detect objects in front of the vehicle.

[0034] To protect the radar 16 from environmental influences such as stone chips, dirt, and / or water, the lens 18 is designed as a radome 22. For the radar beams generated by the radar 16 to exit the headlight 12, the lens 18, or radome 22, must be transparent. Furthermore, to allow the radar beams to exit, the lens 18 must be kept free of snow and / or ice. A heating element 24 is integrated into the lens 18 for this purpose.

[0035] As through a synthesis of Fig. As can be seen in Figures 1 to 3, the heating device 24 has a heating wire 26 applied in a meandering pattern to the light disc 18, a Fig. 1 schematically represented control device 28, one in Fig. 1 schematically represented power source 30, which is connected to the control device 28 and the heating wire 28, and one in Fig. 1 schematically represented temperature sensor 32, which is connected to the control unit 28.

[0036] The ambient temperature is measured by the temperature sensor 32 and transmitted to the control unit 28. The control unit 28 compares the measured temperature with a predefined temperature limit. If the measured temperature is equal to or below the predefined temperature limit, the control unit 28 activates the power source 30, which could be, for example, a vehicle battery. This supplies current to the heating wire 26 via the power source 30, causing it to heat up. As a result, the lens 18 or the radome 22 heats up, melting any snow and / or ice on it.

[0037] For the integration of the heating device 24 or the heating wire 26 into the lens 18 or the radome 22, the lens 18 has the following: Fig. The structure shown in section 3 is based on this.

[0038] As in Fig. As can be seen in Figure 3, the light disc 18 has a transparent film 34 on which the heating wire 26 is applied, an outer first layer 36 made of a transparent plastic and an inner second layer 38 made of a transparent plastic.

[0039] The film 34 is made of a transparent plastic, for example polycarbonate (PC), and has a thickness between 0.2 mm and 0.8 mm, in particular a thickness of 0.5 mm.

[0040] The heating wire 26 is bonded to the foil 34. For this purpose, the heating wire 26 can be glued to the foil or, for example, welded to the foil by means of ultrasonic welding.

[0041] Furthermore, as a design measure, a black print 35 is applied to the transparent film 34. The black print allows for the creation of delicate contours on the light disc 18 or the radome 22.

[0042] The first layer 36 and the second layer 38 are made of a transparent plastic, for example, polycarbonate (PC). The first layer 36 has a thickness between 1 mm and 5 mm, in particular a thickness of 2.8 mm. The second layer 38 has a thickness between 1 mm and 5 mm, in particular a thickness of 3.5 mm. The first layer 36 and the second layer 38 are injection-molded onto the film 34 and thus bonded to the film 34.

[0043] As in Fig. As can be seen in Figure 3, a transparent lacquer layer 40 is applied to the first layer 36, which protects the lens 18 or the radome 22 from stone chips.

[0044] The following describes a possible method for manufacturing the light disk 18, which is designed as a radome 22. In a first step, the transparent polycarbonate film 34 is prepared. In a second step, the heating wire 26 is applied to the film 34 by laying the heating wire 26 in a meandering pattern on the film 34 and bonding it to the film, for example, by gluing or ultrasonic welding. Subsequently, in a third step, the film 34, together with the applied heating wire 26, is placed in a forming tool (not shown), and the forming tool is closed. In a fourth step, the first layer 36 and the second layer 38 are injection-molded onto the film 34. During the injection molding of the transparent plastic, the film 34 is melted, so that the transparent plastic of the two layers 36 and 38 bonds to the film 34.In a fifth step, the forming tool is opened and the light disc 18 is removed. In a sixth step, the clear coat layer 40 is applied to the first layer 36, for example by spraying.

[0045] By integrating a heating device 24 into the headlight 12 according to the invention, it is possible to heat the lens 18, which is designed as a radome 22, and thus keep it free of snow and ice. Furthermore, the headlight 12 has a simple and cost-effective design due to the heating device 24 integrated into the lens 18. Reference symbol list 10 vehicles 12 headlights 13 cases 14 light bulbs 16 Radar 18 Light disc 22 Radome 24 Heating system 26 heating wire 28 Control unit 30 Power source 32 Temperature sensor Slide 34 35 Black print 36 first shift 38 second shift 40 coats of lacquer QUOTES INCLUDED IN THE DESCRIPTION

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

[0000] DE 10 2017 131 441 A1

[0003] DE 100 26 454 C1

[0004] DE 10 2022 107 861 A1

[0005]

Claims

[1] Headlight (12) for a vehicle (10), comprising at least one light source (14) for generating light beams, at least one radar (16) for generating radar beams and at least one light disk (18) designed as a radome (22), characterized by , that a heating device (24) is integrated into the light lens (18). [2] Headlight (12) according to claim 1, characterized by , that the light disk (18) has a first layer (36) made of a transparent plastic, a second layer (38) made of a transparent plastic and a film (34) arranged between the two layers (36, 38), wherein the heating device (24) is applied to the film (34). [3] Headlight (12) according to claim 2, characterized by , that the heating device (24) is materially bonded to the foil (34). [4] Headlight (12) according to any one of the preceding claims, characterized by that the heating device (24) has a heating wire (26). [5] Headlight (12) according to one of claims 2 to 4, characterized by , that the first layer (36) has a thickness between 1 mm and 5 mm, that the second layer (38) has a thickness between 1 mm and 5 mm and that the film (34) has a thickness between 0.2 mm and 0.8 mm. [6] Headlight (12) according to any one of the preceding claims, characterized by , that a black print is applied to the foil (34). [7] Headlight (12) according to any one of the preceding claims, characterized by , that a layer of lacquer (40) is applied to one of the layers (36, 38). [8] Headlight (12) according to any one of the preceding claims, characterized by , that the transparent plastic of the two layers (36, 38) and / or the film (34) is made of a thermoplastic material. [9] Method for manufacturing a light lens (18) for a headlight (12) according to any one of claims 1 to 8, comprising the following steps: a. Applying a heating wire (26) to a foil (34); b. Inserting the foil (34) together with the heating wire (26) into a forming tool and closing the forming tool; c. Injection molding a first layer (36) of a transparent plastic and a second layer (38) of a transparent plastic onto the film (34), such that the film (34) and the heating wire (26) are arranged between the two layers (36, 38); and d. Opening and removing the light disc (18) from the forming tool. [10] Vehicle (10) with at least one headlight (12) according to one of claims 1 to 8 and / or with at least one headlight (12) comprising a lens (18) manufactured by a method according to claim 9.

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