Light module, method for operating a light module and motor vehicle

Abstract

The invention relates to a light module (4 or 6) for a motor vehicle (2) comprising: at least one first semiconductor light source (26), at least one first front optic (22) and at least one first projection optic (30) for emitting a main light distribution (12), in particular a low beam distribution and / or a high beam distribution, which is emitted along an optical axis (32) from the light module (4 or 6); and at least one second semiconductor light source (36), at least one second front optic (34) and at least one second projection optic (37) for emitting a side light distribution (14a, 14b), which is emitted from the light module (4 or 6) deviating from the optical axis (32).

Description

[0001] The invention relates to a light module, a method for operating a light module and a motor vehicle. State of the art

[0002] US 2020 / 0378576 A1 already discloses a light module with a specially shaped projection lens. Deflection optics are arranged to the side of the projection lens, which are used to shape the beam for a side light distribution.

[0003] EP2620697B1 discloses a module with laterally arranged light sources and refractive optics for side light distribution.

[0004] According to US 2023 / 0093629 A1, reflective components are used for the optics of side illumination.

[0005] DE10140277A1 discloses two separate light modules for a main light distribution and a side light distribution. Disclosure of the invention

[0006] The object of the invention is to create a cost-effective light module with a main and a side light distribution.

[0007] This problem is solved using the features of claim 1.

[0008] According to the invention, a light module for a motor vehicle comprises at least one first semiconductor light source, at least one first front optic, and at least one first projection optic for emitting a main light distribution, in particular a low beam distribution and / or a high beam distribution, which is emitted along an optical axis from the light module; and at least one second semiconductor light source, at least one second front optic and at least one second projection optic for emitting a side light distribution which is emitted from the light module in a manner deviating from the optical axis.

[0009] The light module according to the invention enables extended side illumination when the vehicle is turning and cornering. According to the invention, no additional light module dedicated solely to side illumination is required in the headlight to achieve this side illumination.

[0010] Advantageously, experience with existing light modules can be utilized, as these can be extended to include side illumination for cornering without requiring the development of a separate light module and its integration elsewhere – for example, in the bumper. Such existing light modules, which can be extended to include side illumination, can be, in particular, monofunctional, bifunctional, or ADB bifunctional light modules. These light modules can be equipped with wider side illumination using only a few additional components, for example, to implement or integrate additional functions such as static cornering lights, turning lights, or fog lights. By expanding the functionality of existing modules while maintaining as many parts as possible, a cost-effective functional upgrade is possible. Depending on the design, a light module can illuminate both sides – i.e.,The lighting can be extended to the left and right sides. Alternatively, only one of the two sides – i.e., left or right – can be extended to include side lighting.

[0011] Moreover, the manufacturing costs of the light module according to the invention can be low, since a separate light module for side illumination is not required. Because the "side illumination" functionality is integrated into the light module for the main light distribution – in particular the low beam – only a small number of parts are needed, thus keeping costs down.

[0012] Advantageously, a main reflector aperture section can be arranged between the at least one first front optic and the first projection optic, at least partially. This main reflector aperture section can advantageously separate different semiconductor light sources for generating various lighting functions. For example, high beam and / or low beam can be separated from cornering lights. Furthermore, matrix lighting functions can be optically separated by means of the main reflector aperture section to avoid dazzling pedestrians and oncoming vehicles.

[0013] It is also possible to arrange a side reflector aperture section, at least partially, between the at least one second front-mounted lens and the second projection lens. This allows the light from the "side illumination" to be separated from a cornering light or other lighting function.

[0014] In a cost-effective and compact manner, the main and side reflector aperture sections can be provided by a common reflector aperture component.

[0015] The second projection optic can be advantageously a deflecting optic, which - is positioned laterally offset to the optical axis and - deflects the side light distribution in a direction perpendicular to the optical axis.

[0016] It can be provided that the main light distribution is coupled out at an exit surface of the first projection optics and that the side light distribution crosses the main light distribution on the side of the exit surface.

[0017] A simple geometry can be created by using the side reflector aperture section - lies in a common plane with the main reflector aperture section or - is located parallel to and offset from the main reflector aperture section.

[0018] It can be advantageous to provide that the main light distribution is coupled out at an exit surface of the first projection optics and that the side light distribution crosses the main light distribution on the side of the exit surface.

[0019] It can be advantageous to mount the two semiconductor light sources on a common circuit board.

[0020] It can be advantageous to provide that the circuit board is coupled with a heat sink that extends in the direction of the circuit board and thereby overlaps the two semiconductor light sources and dissipates heat from both semiconductor light sources.

[0021] Advantageously, the first front optic may have pattern-like repeating shape elements that are connected in one piece and each has its own semiconductor light source and its own optical axes, and the second front optic has at least one further shape element with the second semiconductor light source, wherein an optical axis of the shape element of the second front optic is not parallel to the optical axes of the shape elements of the first front optic.

[0022] It may be advantageous to provide that the further form element with the second semiconductor light source is separate from the form elements of the first attachment optic.

[0023] It can be advantageous to provide that the deflecting optics are a reflection optics made of a different material than the first projection optics and are arranged laterally, in particular on both sides of the first projection optics.

[0024] Alternatively, the deflecting optics can be integrated as a single unit with the first projection optics. The deflecting optics can also be positioned laterally, particularly on both sides of the first projection optics.

[0025] The invention further relates to a method for operating a light module. The following method steps are carried out: - Extracting a main light distribution from a first front-mounted optic, - Guiding a collimated light distribution parallel to a plane of a main reflector aperture section, - Coupling the main light distribution into and out of a first projection optic, - Extracting a side light distribution from a second front-mounted lens, and - Deflection of the side light distribution in a direction perpendicular to the optical axis.

[0026] The invention further relates to a motor vehicle with two light modules. The first light module is arranged on the left side of the front of the motor vehicle, whereas the second light module is arranged on the right side of the front of the motor vehicle.

[0027] They show: Fig. 1 a motor vehicle with two light modules, Fig. 2 components within one of the light modules in a first embodiment, Fig. 3 the components from Fig. 2 and additionally a side light distribution, Fig. 4 using a diagram for the exemplary embodiment according to Fig. 2 and Fig. 3 a main light distribution, Fig. 5 in a representation analogous to Fig. 4 a side light distribution, Fig. 6 in a representation analogous to Fig. 4 and Fig. 5 a combination of the main light distribution and the side light distributions, Fig. 7 components within one of the light modules in a second embodiment, Fig. 8 the components from Fig. 7 and additionally a side light distribution, Fig. 9 components within one of the light modules made of Fig. 1 in a third embodiment, Fig. 10a the components from Fig. 9 and additionally a side light distribution, Fig. 10b in a detail from Fig. 10a the sidelight distribution, showing possible focal lengths, and Fig. 11. Determine the sidelight distribution using a diagram. Fig. 10a and Fig. 10b. Fig. 12 components within one of the light modules in a fourth embodiment wherein a side light distribution is assigned to a diagram.

[0028] Fig. Figure 1 shows a motor vehicle 2 with two light modules 4 and 6. The first light module 4 is located on the left side of the front of the motor vehicle 2. The second light module 6 is located on the right side of the front of the motor vehicle 2. The two light modules 4 and 6 have light cones 8 and 10 respectively, each with a main light distribution 12.

[0029] Motor vehicle 2 can steer to the right or left by means of steerable wheels. Therefore, motor vehicle 2 can turn right or left. Before and during the turn, the two light modules 4 and 6 illuminate the roadway and adjacent areas, such as a pedestrian walkway, houses, trees, meadows, etc., with a side light distribution 14a, 14b and 16a, 16b, respectively. The brightness of the side light distribution 14a, 14b, 16a, 16b is lower than the brightness of the main light distribution 12. In a horizontal plane of the vehicle 2 and the light modules 4, 6, the two-part side light distribution 14a, 14b and the also two-part side light distribution 16a, 16b open over a considerably larger angle than the light cones 8 and 10 of the main light distributions 12 and 10, respectively. Therefore, each of the two light modules 4, 6 is extended on both sides – i.e., left and right – by a side illumination 14a and 14b, respectively, and 16a and 16b, respectively.

[0030] However, in an alternative embodiment not shown in the drawing, only the outer surface of each light module 4 or 6 can be illuminated by means of a side light distribution 14a or 16a, respectively. That is, in this case, only the side light distribution 16a of the right light module 6 shines, and specifically to the right. Conversely, in this case, only the side light distribution 14a of the left light module 4 shines, and specifically to the left.

[0031] The two light modules 4 and 6 are identical in design. That is, the two light modules 4 and 6 are mirror images of each other with respect to a perpendicular longitudinal plane of the vehicle.

[0032] The light modules 4, 6 each have a housing 18 which is closed on the outside of the motor vehicle 2 by a transparent cover 20. The main light distribution 12 and the side light distributions 14a, 14b and 16a, 16b respectively pass through, i.e., transmit, the cover 20.

[0033] The following will be based on the Fig. Sections 2 to 8 explain one of the two light modules 4, 6, light module 4. This light module 4 is illustrated in two embodiments.

[0034] Fig. 2 and Fig. Figure 3 shows components for the first embodiment of one light module 4, which are located inside the housing 18 of Fig. 1 or Fig. 12 are arranged.

[0035] The aforementioned components within the housing 18 of the light module 4 exhibit: - a first front optic 22 from which the main light distribution 12 of several first semiconductor light sources 26 is emitted, - a reflector aperture component 28, which extends substantially in a plane that lies in the plane of the drawing sheet, - a first projection optic 30, into which the main light distribution 12 is coupled in and out, wherein an optical axis 32 of the projection optic 30 lies parallel to the plane of the reflector aperture component 28, - two second front optics 34 with two second semiconductor light sources 36, from which the side light distributions 14a, 14b are emitted, - a second projection optic 37 comprising two deflection optics 38, which - are arranged laterally offset to the optical axis 32 and - deflect the side light distributions 14a, 14b in a direction perpendicular to the optical axis 32.

[0036] The first semiconductor light sources 26 and the second semiconductor light sources 36 are preferably light-emitting diodes (LEDs), which may be surface-mount devices (SMDs). The first semiconductor light sources 26 of the main light distribution 12 and the second semiconductor light sources 36 of the side light distribution 14a, 14b are mounted on a front side of a common printed circuit board 40, which is only in Fig. Figure 3 is shown graphically. The front side is also referred to as the PCBA layer, where "PCB" stands for "Printed Circuit Board".

[0037] The circuit board 40 is coupled on its back side to a heat sink 41, which extends towards the circuit board 40 and thus overlaps both the first semiconductor light sources 26 and the second semiconductor light sources 36 and thus dissipates heat from all these semiconductor light sources 26, 36 that is generated during the operation of these semiconductor light sources 26, 36.

[0038] Using these semiconductor light sources 26, 36, images are projected in an intermediate image plane by means of the first and second front optics 22, 34, which are also referred to as primary optics 24, which are in Fig. The main light distribution 12 shown in Figure 1 and the side light distributions 14a, 14b are generated. The primary optic 24 is, in particular, a reflection optic designed as a TIR optic. TIR stands for "Total Internal Reflection" and means that the light is completely reflected at an interface between two media. Therefore, contrary to the graphic representation, the semiconductor light sources 26, 36 can also be arranged above the drawing planes, and radiate in the direction of the reflector aperture component 28 and wherein the prism-like primary optics 24 preferably reflects the light distribution emitted by the semiconductor light sources 26, 36 at a 90° angle, so that a collimated light distribution parallel to the reflector aperture component 28 is then radiated in the direction of the first projection optics 30 and coupled into it.

[0039] The main light distribution 12 generated by means of the front optic 22 is guided by means of the front optic 22 along the reflector aperture component 28, which is designed as a mirror aperture and is arranged between the first front optic 22 and the first projection optic 30.

[0040] The reflector aperture component 28 has a main reflector aperture section 27 with a concave edge 48. The main reflector aperture section 27 forms the central part of the reflector aperture component 28. However, the main reflector aperture section 27 does not necessarily have to be located centrally. In particular, if, in contrast to the exemplary embodiment, only a right-side or a left-side side light distribution 14a or 14b is provided, the main reflector aperture section 27 does not necessarily have to be central, but can also form a lateral part of the reflector aperture component 28.

[0041] The main light distribution 12 is coupled into a projection lens 44 of the projection optics 30. The light coupled in there is refracted by the projection lens 44. The maximum possible angle of the light cone 8 or 10 of the respective projection lens 44 is technically limited by the effect of total internal reflection. It is therefore physically impossible to simultaneously generate low beam and cornering light with a single projection lens 44. This, however, disadvantageously prevents illumination of the sides when cornering.

[0042] The first front optic 22 is a single piece and features a multitude of transparent, visible-light-transparent elements that repeat in a pattern. Each of these repeating elements has its own light source 26 and its own optical axis 50. These optical axes 50 are slightly inclined towards the optical axis 32 of the projection lens 44.

[0043] Each of the two second optic attachments 34 also has several shape elements transparent to visible light. Each of the two second optic attachments 34 has fewer shape elements than the first optic attachment 22.

[0044] Each of the design elements of the two second optics 34 has its own second semiconductor light source 36. One of the second optics 34 is positioned to the left of the first optic 22, while the other is positioned to the right of the first optic 22. The design elements of the second optics 34 also have optical axes 52, which are slightly inclined towards the optical axis 32 of the projection lens 44, so that each of the two side light distributions 14a, 14b is directed towards one of the two deflecting optics 38.

[0045] The design elements of the second attachment optics 34 can be separate from the design elements of the first attachment optics 22. Alternatively, the design elements of the second attachment optics 34 can also be manufactured as a single unit with the design elements of the first attachment optics 22.

[0046] Side reflector aperture sections 54 are arranged on both sides and to the side of the main reflector section 27, which together with the main reflector section 27 provide the reflector aperture component 28.

[0047] The deflecting optic 38 is a reflection optic made of a different material than the projection optic 30. The reflection optic is in two parts and is arranged to the side, left and right of the projection optic 30.

[0048] Such a reflective optic is indeed an additional component compared to a light module without side light distribution or compared to the light module of the second embodiment described below. However, a projection lens holder, which also holds the projection lens 44, can be used cost-effectively for positioning the reflective optic.

[0049] The side light distributions 14a, 14b are not coupled into the projection lens 44, but instead are deflected by means of the deflecting optics 38 and guided past the projection lens 44. The side light distributions 14a, 14b thereby intersect the main light distribution 12 on the side of the exit surface 42. The side light distributions 14a, 14b are spaced apart from the exit surface 42.

[0050] In contrast, the main light distribution 12 is not shown for the sake of clarity. Fig. 3 shown, but in Fig. 4. The main light distribution 12 is coupled out at the exit surface 42 of the projection lens 44.

[0051] The in Fig. The 5 depicted side light distributions 14a, 14b extend the main light distribution 12 to a wider overall light distribution 58, which is shown in Fig. 6 is shown.

[0052] Fig. 7 and Fig. Figure 8 shows components for the second embodiment of the light module 4, which are arranged within the housing 18 of the light module 4. Only the differences from the first embodiment will be discussed below. Otherwise, the explanations for the first embodiment, including the alternatives mentioned for the first embodiment, apply.

[0053] The deflecting optic 138 of the second embodiment is designed as a single unit with the projection lens 144.

[0054] To enable this single-piece design and the use of the same material, the deflecting optic 138 consists of refractive surfaces. These refractive surfaces refract light and can be provided with microstructured surfaces. The refractive surfaces are mathematically independent of the central projection lens 144.

[0055] Fig. Figures 9 to 12 show a third and a fourth embodiment of the light module 4. In these two embodiments, cost and design advantages over individual modules are achieved by using a common PCB for all functions. The side light distribution and a main light distribution are cooled by a common heat sink located on the back of the PCB, which overlaps both the first semiconductor light sources 226 and the second semiconductor light sources 236. Furthermore, in the light modules of the third and fourth embodiments, each a common first attachment optic 222, a common projection optic 230 and a common lens holder (not shown in detail in the drawing) planned.

[0056] Fig. 9 and Fig. Figure 10 shows components arranged inside the housing of the light module for the third embodiment of the light module.

[0057] The additional semiconductor light sources 236 required for side light distribution are placed together with the first front-mounted optics 222 for the high beam and / or the low beam on a common circuit board.

[0058] The first front-mounted optic 222 has been extended to include side light distribution.

[0059] In this third embodiment, the light module has a particularly thin and cost-effective design. The light module is designed as a low-profile module by implementing the first optic 222 as a solid-body optic. In this solid-body optic design, a transparent, flat light guide 253 is integrally connected to the TIR collimators, with convex exit surfaces 255. In an alternative embodiment, a prism-like element can be integrated into the solid body, deflecting the light from the semiconductor light sources by 90°.

[0060] The light emitted by the first semiconductor light sources 226 is guided by the TIR collimators of the first front optic 222 into its light guide 253. A light distribution to be imaged is generated in the region of a mirror aperture edge located within the light guide 253. This light distribution is projected onto the road surface in front of the vehicle as the main light distribution via the lens-shaped exit surfaces 255 and a projection lens 244 of the projection optic 230. For this purpose, the projection lens 244 has a curved or flat entrance surface 256 and a convex exit surface 257. Thus, the main light distribution, i.e., in particular a low beam distribution and / or a high beam distribution, is emitted from the light module via the projection lens 244 along an optical axis 232.

[0061] A second optic 237, responsible for side light distribution, is arranged to the side of the first optic 222. This second optic 237 is also designed as a TIR collimator, but is physically separate from the TIR collimators of the first optic 222. In an alternative embodiment, not shown in the drawing, the two optics 222 and 237 are integrally connected.

[0062] To the side of the light guide 253 are - an optical surface 264 or a mirror aperture 258 and - An optical surface 265, or a first lens 259, is arranged. This first lens 259, or the associated optical surface 265, is part of the front optics 237. A second lens 260 has an entrance surface 261 and an exit surface 262. The entrance surface 261 and the exit surface 262 of the second lens 260 are connected to the projection lens 244. This connection can be a single piece or can be achieved using separately prefabricated parts that are glued, welded, solvent-welded, etc., together. The second lens 260 can overlap an edge of the first projection optics 230.

[0063] The optical surfaces of the projection lens 244 are therefore assigned to it. These optical surfaces are the entrance surface 261 and the exit surface 262 of the second lens 260. The entrance surface 261 and the exit surface 262 are thus rigidly connected to the projection lens 244 to form a single component. This component can preferably be made of polymethyl methacrylate (PMMA).

[0064] The - first lens 259 or the optical surface 265, - the mirror aperture 258 or the optical surface 264 and - The TIR collimators 263 of the second front optic 237 are preferably manufactured in one piece with the first front optic 222 or are permanently connected to each other to form a single component. This component may preferably be made of polycarbonate (PC). On this component - the first lens 259 or the optical surface 265, - the mirror aperture 258 or the optical surface 264 and - the TIR collimations 263 of the second front optics 237 are thus represented by optical surfaces 263, 264, 265 on the said component.

[0065] Fig. Figure 10a shows the resulting beam path 270 of the light distribution of a cornering light or side light distribution. Furthermore, the optical function of the individual optical surfaces 261, 262, 263, 264, 265, 237, 258, 259 for the side light distribution to implement the cornering light is shown. The surface 265 of the first lens 259 maps the real focal point F1, which lies in an aperture plane of the mirror aperture 264, onto a virtual focal point F2, which lies on an optical axis 266 that is inclined to the optical axis 232 or to a main emission direction 200 in the direction of travel. The entrance surface 261 of the second lens 260 then maps the virtual focal point F2 onto another virtual intermediate focal point F3, which lies on optical axis 267, which in turn is also inclined to optical axis 232 or to the main emission direction 200 in the direction of travel. However, optical axis 267 is inclined more strongly to optical axis 232 than optical axis 266.In this context, "stronger" means that an angle β between axes 267 and 232 is larger than an angle α between axes 266 and 232. The resulting image is formed by the exit surface 262 of the second lens 260, which maps the virtual focal point F3 onto a focal point F4 located 25 m away. This focal point F4 lies on an optical axis 268, which forms an angle δ of at least 25°, preferably about 30°, with the optical axis 232. Therefore, the following holds true for the angles: δ > β > α.

[0066] In Fig. Figure 10b shows advantageous focal lengths |F1|, |F2|, |F3|, and |F4| for the aforementioned focal points F1, F2, F3, and F4. The ranges in which the angles α, β, and δ can advantageously assume are also described. The angles α, β, and δ describe the positions of the optical axes relative to the principal emission direction. Furthermore, preferred angular dimensions are shown.

[0067] The focal length |F1| of the actual focal point F1 can advantageously be approximately 25 mm. Twice this focal length |F1| is less than or equal to the focal length |F2|. The focal length |F2| is less than or equal to the focal length |F3|.

[0068] The focal length |F3| is much smaller than the focal length |F4|, which is approximately 25m.

[0069] The angle α lies in the range between 5° and 15°. The angle α is preferably 10°.

[0070] The angle β lies in the range between 15° and 25°. The angle β is preferably 20°.

[0071] The angle δ is greater than 25°. The angle δ is preferably 30°.

[0072] Fig. Figure 11 shows the side light distribution 100 of the cornering light generated by the light module of the third embodiment. In the third embodiment, a 1 lux line 100a lies horizontally at -70° with a light module mounted on the left side of the vehicle.

[0073] Fig. Figure 12 shows, for the fourth embodiment, the housing 18 of a left light module 4, which in itself has no side light distribution. Furthermore, a housing extension 300 is shown by means of a dashed line, with which the housing 18 is extended to include the side light distribution. Within the housing extension 300, the side light distribution 101 is divided into two light distributions 101a and 101b.

[0074] The light module 4 is shown in a vertical section. In this vertical section, the contour of the exit surface 362 of the second lens 360 seamlessly connects to the exit surface 357 of the projection lens 344. In addition to the front optic 470 provided for side light distribution 101, a further front optic 471 is provided. Both front optics 470 and 471 are each designed as TIR collimators. As can be seen from the lower part of Fig. As can be seen in Figure 12, the entire side light distribution 101 is extended in the width of the horizontal illumination compared to the first to third embodiments. Thus, in addition to the light distribution 101a, the additional light distribution 101b is provided compared to the first to third embodiments. This additional distribution can be switched on or off as needed and can therefore extend the horizontal illumination by means of cornering lights in two stages. 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] US 2020 / 0378576 A1

[0002] EP 2620697B1

[0003] US 2023 / 0093629 A1

[0004] DE 10140277A1

[0005]

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