Air guide element for a ventilation system and vehicle headlights

Abstract

The invention relates to an air guide element (100) for a ventilation system of a vehicle headlight, comprising at least one component body (1) with at least one internal air guide channel, wherein the component body (1) is designed as a composite of at least two shell elements (11, 12). According to the invention, the shell elements (11, 12) are manufactured from a foamed plastic by thermoforming.

Description

[0001] The present invention relates to an air guide element for a ventilation system of a vehicle headlight and to an associated vehicle headlight. STATE OF THE ART

[0002] Vehicle headlights feature ventilation systems for thermal management during the operation of the integrated light modules. These systems primarily serve to prevent overheating and moisture buildup from condensation inside the headlights. Key components of these ventilation systems are air guide elements, which, in combination with active fans or through the strategic use of convection currents, ensure proper air circulation within the headlights. For example, air heated by the light sources is drawn away from the associated light modules or heat sinks and directed towards the headlight lens for further heating, thus suppressing unwanted condensation. The air guide elements incorporate internal air channels through which the airflow is directed.In the prior art, air guide elements are usually assembled from shell elements manufactured by injection molding. REVELATION OF THE INVENTION

[0003] The object of the present invention is to propose an alternative embodiment of air guide elements for ventilation systems, which is characterized in particular by low weight and resource-saving manufacturing.

[0004] This problem is solved by an air guide element according to claim 1. Advantageous embodiments of the invention are specified in the dependent claims.

[0005] Starting from an air guide element with a component body consisting of at least two shell elements, the invention discloses that the shell elements are made of a foamed plastic by means of thermoforming.

[0006] The invention is based on the idea of ​​achieving a significant weight reduction of the air guide element while simultaneously improving its thermal insulation properties by using a foamed plastic instead of the solid material commonly used in the prior art. The shell elements made of foamed plastic exhibit a suitable degree of porosity for this purpose. To manufacture the shell elements, a semi-finished product, in particular a film or sheet, made of foamed plastic is thermoformed. This allows the more resource-, energy-, and cost-intensive injection molding process to be replaced. In thermoforming, also known as hot forming or thermoforming, film- or sheet-shaped semi-finished products made of a thermoplastic material are heated until they become malleable and then drawn into a mold using a vacuum or compressed air.After cooling and demolding, the components, in this case the shell elements, are punched out of the molded parts.

[0007] To form the component body, the shell elements are joined together, in particular by means of welded or adhesive bonds. For example, a welded joint can be created immediately after thermoforming by pressing the still-warm shell elements together, forming a material-bonded joining zone.

[0008] The shell elements have wall thicknesses ranging from approximately 0.5 mm to 3 mm. Within this range, depending on the specific plastic used and its porosity, suitable component properties can be achieved with regard to mechanical strength, airtightness, and thermal insulation. Polypropylene is a particularly suitable plastic for this purpose. The air duct running within the component body, for example, has a diameter ranging from 10 mm to 60 mm, with the diameter being adjustable along the duct as needed.

[0009] In one embodiment, the air guide element comprises at least one receiving element for connection to the vehicle headlight, wherein the receiving element is positively connected to the component body by means of an adhesive bond or a weld. Suitable receiving elements include, for example, screw bosses or snap hooks. Their geometries and wall thicknesses are typically not achievable by thermoforming, so injection-molded components are often used. These can be positively connected to the shell elements as inserts during the thermoforming process. Alternatively, receiving elements can be integrally molded onto the shell elements in one piece and of a single material during thermoforming, provided the thickness of the semi-finished product used is appropriately dimensioned.

[0010] The invention further relates to a vehicle headlight, comprising at least a light module and a ventilation system for heat management during operation of the light module, wherein the ventilation system has at least one air guide element according to one of the aforementioned embodiments. PREFERRED EXAMPLE OF THE INVENTION

[0011] An embodiment of the invention is illustrated and described in more detail below with reference to the figures.

[0012] Fig. 1a and Fig. Figure 1b shows perspective views of an air guide element 100 according to the invention for a ventilation system of a vehicle headlight. It comprises the component body 1 with an internal air guide channel, wherein the component body 1 has a complex freeform shape with a plurality of channel openings 10 that open into the air guide channel as air inlet and air outlet openings.

[0013] According to the invention, the component body 1 is formed as a composite of two shell elements 11, 12, each of which is made of a foamed plastic by thermoforming. The two shell elements 11, 12 are welded together along the circumferential joining zone 13.

[0014] Furthermore, the air guide element comprises 100 mounting elements 2, which are intended for connection to the associated vehicle headlight. The mounting elements 2 are designed as injection-molded components with higher mechanical strength and are positively connected to the component body 1. Reference symbol list 100 air guide elements 1 Component body 10 Channel opening 11, 12 shell element 13 Joining zone 2 recording devices 5acXjzUk

Claims

Air guide element (100) for a ventilation system of a vehicle headlight, comprising at least a component body (1) with at least one internal air guide channel, wherein the component body (1) is designed as a composite of at least two shell elements (11, 12), characterized in that the shell elements (11, 12) are made of a foamed plastic by thermoforming. Air guide element (100) according to claim 1, characterized in that the shell elements (11, 12) are connected to each other by means of welded connections or by means of adhesive connections. Air guide element (100) according to claim 1 or 2, characterized in that the shell elements (11, 12) have wall thicknesses in the range of 0.5 mm to 3 mm. Air guidance element (100) according to one of the preceding claims, characterized in that the air guidance channel has a diameter in the range of 10 mm to 60 mm. Air guide element (100) according to one of the preceding claims, characterized in that the foamed plastic comprises polypropylene. Air guide element (100) according to one of the preceding claims, characterized in that the air guide element (100) comprises at least one receiving means (2) for connection with the vehicle headlight, wherein the receiving means (2) is positively connected to the component body (1) by means of an adhesive connection or by means of a welded connection. Vehicle headlight, comprising at least a light module and a ventilation system for heat management during operation of the light module, characterized in that the ventilation system has at least one air guide element (100) according to one of the preceding claims.

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