Lighting device for a motor vehicle and method for repairing a lighting device

Abstract

The invention relates to a lighting device for a motor vehicle, comprising a housing (10), at least one light source received in the housing (10), and a lens (12) that closes an opening (11) of the housing (10) to the outside. Various embodiments are presented that facilitate disassembly and subsequent reassembly of the lighting device for the purpose of repair or improved recycling. Among other things, it is proposed that the housing (10) has two ribs (10a, 10b) pointing in a main emission direction (HA) of the lighting device (1b), which surround or delimit the opening (11) of the housing (10) and which extend at a distance from each other, with a circumferential groove (10c) being formed by this distance.A circumferential rib (16) of the light disc (12) projects into the groove (10c), the light disc (12) being detachably connected to the housing (10) at fastening points (B) with a part (12a) that overlaps the housing (10).

Description

[0001] The invention relates to a lighting device for a motor vehicle with the features of the preamble of claim 1. The invention also relates to a method for repairing a lighting device according to claim 4.

[0002] Modern automotive lighting devices, particularly headlights and taillights, feature a lens that seals the housing and is typically welded to the housing by friction or laser welding, thus creating a permanent bond. Repairing or replacing components within the housing is therefore extremely difficult or even impossible. Furthermore, this design also complicates the process of separating different materials (electronic circuit boards, plastics, etc.) for recycling at the end of the product's lifespan.

[0003] US Patent 6,149,288 A discloses a lighting device comprising a base plate, a circuit board with light sources mounted on it, and a light lens screwed onto the base plate. If the circuit board fails, it can be replaced after unscrewing the light lens.

[0004] US Patent 6,254,262 B1 describes a signal light for motor vehicles, comprising a housing closed at the rear by a back panel and at the front by a lens. The housing contains several light sources and a circuit board that controls them. The back panel is equipped with cooling fins for heat dissipation. The back panel is screwed to the housing and can be unscrewed for servicing. A second lens is screwed onto the lens that closes the housing. This is intended to allow for the replacement of the outer lens during servicing.

[0005] CN 207364947 U describes a rear light for a motor vehicle, consisting of a housing and a lens enclosing it. Several spring-loaded retaining pins extend through the housing, their ends engaging a correspondingly shaped inner area of ​​the lens. At the opposite end, the retaining pins are connected to a handle. By sliding the handle, the retaining pins can be moved into a locking or release position. This is intended to facilitate easy replacement of a circuit board housed within the casing.

[0006] DE 34 02 275 A1, which also has the features of the preamble of claim 1, describes a headlight in which a lens can be mounted on the housing by means of a toothed directional locking mechanism with multiple locking points, consisting of a rigid locking element and an elastic blocking piece. The interlocking teeth of the locking element and the teeth of the blocking piece are designed as barbs, so that the directional locking mechanism can only be released when the blocking piece is lifted out of the locking element.

[0007] From DE 197 19 832 A1, a headlight for a motor vehicle is known, consisting of a housing made of glass fiber reinforced plastic with a front opening for a lens and a light source with a reflector. A watertight seal between the housing and the lens is formed by a sealant in a trough section of the housing, which accommodates a lip on the circumference of the lens. The assembly is secured by wedge-shaped projections formed on the outside of the housing circumference, which engage in similarly shaped openings of tongue-like parts on the outer edge of the lens. The tongue-like parts are sufficiently elastic to bend outwards when passing over the projections and, in the final position, ensure a secure snap closure.

[0008] German patent DE 103 53 375 A1 describes a vehicle light comprising a housing and a cover lens that closes a light emission opening. The housing contains a lighting module with at least one incandescent lamp reflector or a circuit board equipped with light-emitting diodes. The vehicle light is designed according to a modular system. For this purpose, the lighting module and the housing are connected to each other via an adapter part, whereby the housing and the lighting module are detachably mounted on the adapter part.

[0009] The document number 10 2016 117 160 A1 describes a lighting device for a vehicle, comprising a housing for at least one light source and a lens. The lens is secured by locking hooks that allow it to be detachably locked into place.

[0010] Finally, DE 100 03 063 A1 discloses a motor vehicle headlight comprising a cover lens, a housing, and a seal. The housing and the cover lens form a groove or a wall for engaging in the groove, respectively, so that the seal is clamped between the bottom of the groove and a free edge of the wall. At a point away from the bottom of the groove, the cover lens and the housing form two opposing surfaces that extend transversely to the depth of the groove, such that the seal continues between these two opposing surfaces and is compressed between them. As an alternative, it is also disclosed that the cover lens is detachably held on the housing by a retaining clip.

[0011] The present invention aims to propose an alternative lighting device for a motor vehicle, in which the housing can be opened in a controlled manner to increase or at least facilitate access to components for repair or recycling. At the same time, the lighting device should have an attractive appearance after being properly installed on the motor vehicle. A further objective is to propose a possible method for repairing such a lighting device.

[0012] These problems are solved by a lighting device with the features of claim 1 and a method with the features of claim 4. Advantageous embodiments of the invention are described in the dependent claims.

[0013] The invention relates to a lighting device for a motor vehicle, comprising a housing, at least one light source received in the housing and a light lens that closes off an opening of the housing to the outside.

[0014] According to the invention, the housing has two radially outwardly projecting ribs, which are set back from the opening of the housing and surround the housing at a distance from each other. The ribs preferably run equidistant from each other. This distance forms a circumferential groove. The light lens projects radially beyond an outer edge of the ribs.

[0015] These features ensure that, despite the lens being permanently attached to the housing, the lighting device can be opened in a controlled manner, thus facilitating the replacement of components. In particular, the circumferential groove provides a guide for easily separating the housing, while the circumferential ribs simultaneously offer a point of contact for the subsequent controlled reassembly of the housing parts. Because the lens extends radially beyond the outer edge of the ribs, the ribs are not visible to an observer when the lighting device is installed on the vehicle. This ensures an aesthetically pleasing appearance when the lighting device is mounted.

[0016] Alternatively, the invention proposes that the housing has two ribs pointing in a main emission direction of the lighting device. The ribs surround or define the opening of the housing. Furthermore, the ribs extend at a distance from one another, with this distance forming a circumferential groove. Here, too, the ribs preferably extend equidistant from one another. A circumferential rib of the light disc projects into the groove. Finally, the light disc is detachably connected to the housing at fastening points by a part that overlaps the housing on the outside.

[0017] This design proposes a lighting device in which the housing can be opened and closed even more easily. By detachably connecting the lens to the housing at mounting points with a part that extends beyond the housing, a condition is also created to ensure that, despite the lens's detachability, this feature does not detract from the appearance of a motor vehicle equipped with such a lighting device.

[0018] Following further development, the part of the lens that extends beyond the housing features an opening into which a radial projection of the housing engages. This ensures that the lens is securely held to the housing and can also be easily removed.

[0019] The design incorporates a spring-loaded tab forming the portion of the lens that extends beyond the housing, and a radial projection of the housing forming part of a spring-loaded tab molded onto the housing. This facilitates both the attachment and removal of the lens from the housing.

[0020] According to further features of the invention, it is also proposed that the part of the light disc extending beyond the housing forms a radially outwardly directed groove into which a fastening element projects. The fastening element also projects at least into a groove formed on the housing and directed opposite to the main emission direction.

[0021] In other words, the lens and housing are held together at the mounting point by the fastening element, similar to a clamp. This allows for a reliable fastening and easy removal of the lens, but in an alternative way.

[0022] According to one embodiment of the invention, it is conceivable that the groove on the part of the light lens that overlaps the housing and the groove formed on the housing are arranged offset from each other along the circumference of the lighting device. The grooves on the light lens and on the housing thus alternate along the circumference of the lighting device. The fastening element is then wire-like and circumferential.

[0023] In other words, the fastening element passes through the grooves formed on either side of the lens and the housing. This has the advantage that the fastening element does not need to be loosened at every fastening point, but rather that loosening the fastening element once at one point is sufficient.

[0024] Following further training, it is proposed that a sealing ring be arranged in the circumferential groove into which the circumferential rib of the lens projects. This ensures the tightness of the lens attached to the housing.

[0025] According to a highly advantageous embodiment of the invention, the rib of the light lens projecting into the circumferential groove of the housing is part of a first, frame-like portion of the light lens made of a first, opaque material component. Within this first, frame-like portion, at least a second portion of the light lens made of a second, transparent material component is arranged. The second portion of the light lens is detachably attached to the inside of the first, frame-like portion of the light lens. The second, transparent material component can be colorless or colored.

[0026] These features contribute to even better separability of different materials within the lighting device. For example, the first, frame-like part of the lens could be made of black plastic, and the second part of the lens of transparent, red-tinted plastic. A third part of the lens could be made of transparent, colorless, or orange-tinted plastic. The first, frame-like part could thus serve to cover the lens's mounting points on the housing or parts of the lens on the first, frame-like part. The second part of the lens could support the lighting function of a taillight or brake light. The third part of the lens could support the lighting function of a turn signal or a reversing light.In the event of a defect in part of the lens, only the affected part needs to be replaced. Furthermore, at the end of the vehicle's life cycle, the lens can be separated into its constituent materials.

[0027] As mentioned at the beginning, the present invention also presents a method for repairing a lighting device. Specifically, this concerns a lighting device in which the lens is permanently attached to the housing.

[0028] According to the invention, the method proposes that the housing is first separated between the aforementioned radially outwardly projecting ribs using a suitable tool. The light lens, along with the separated front part of the housing, can then be set aside. Internal components of the lighting device, such as a circuit board with light sources, are now easily accessible. After repair or replacement of defective components, the ribs are positioned and secured against spacers inserted between them.

[0029] Following a further development of the process, the spacers are attached either by an adhesive layer acting on the spacer and the ribs, by a clamping force acting on the ribs, or by screws acting on the spacer and the ribs. All these measures ensure a secure hold of the assembled housing parts. If no adhesive layer is used, a rubber seal between the ribs is recommended.

[0030] A T-shaped or W-shaped spacer is preferably used. This facilitates handling of the spacer during assembly and contributes to a defined fit of the spacer between the ribs. With a W-shaped spacer, a central web is positioned between the ribs and performs the spacing function. The outer legs are preferably inclined towards the ribs and act as a clamp, preferably exerting a spring-like pressure against the ribs from the outside.

[0031] Preferred embodiments of the invention are illustrated in the figures and are explained in more detail in the following description with reference to the figures. This also clarifies further features and advantages of the invention. Identical reference numerals, even in different figures, refer to identical, comparable, or functionally equivalent components. Corresponding or comparable properties and advantages are achieved even if no repeated description or reference is made to them. The figures are not, or at least not always, to scale. In some figures, proportions or distances may be exaggerated to more clearly emphasize features of an embodiment.

[0032] They show, schematically, each one Fig. 1 a sectional view through a lighting device, Fig. 2a a detailed representation according to Detail II from Fig. 1. Before opening the casing for repair purposes, Fig. 2b a detailed representation according to Detail II from Fig. 1, after the housing has been separated and subsequently reassembled, Fig. 3 A detailed representation of a lighting device in a second embodiment, in a comparable area to Detail II from Fig. 1, Fig. 4 a rear view of the lighting device Fig. 3, Fig. 5 a detailed representation of a lighting device in a third embodiment, in a comparable area to Detail II from Fig. 1 and according to section view V from Fig. 6, Fig. 6 a perspective rear view of the lighting device Fig. 5, Fig. 7 a detailed representation of a lighting device in a fourth embodiment, in a comparable area to Detail II from Fig. 1 and according to section VII from Fig. 8 and Fig. 8 a view of the lighting device Fig. 7 opposite a main radiation direction.

[0033] In the Fig. Figure 1 shows a sectional view of a lighting device 1a. The lighting device 1a is designed as a rear light. It has a housing 10 in which a reflector 15 and at least one light source 14 arranged on a circuit board 13 are accommodated. The light source 14 is preferably designed as a light-emitting diode (LED). Light rays L generated by the light source 14 are reflected by the reflector 15 towards a lens 12, which closes a front opening 11 of the housing 10 to the outside. The light rays L pass through the lens 12 and radiate in the direction of a main emission direction HA. Both the housing 10 and the lens 12 are preferably manufactured as injection-molded plastic components.

[0034] To allow for repair in the event of a defect in the circuit board 13 or the light source 14, the lighting device 1a has a specific design in the area where the light lens 12 is connected to the housing 10. This is illustrated by the Fig. 2a will be explained in more detail: The light lens 12 is thus permanently connected in the area of ​​the opening 11 to a bridge 16 pointing towards the housing 10 at a contact surface K of the housing 10. The permanent connection between the light lens 12 and the housing 10 was previously preferably achieved by friction or laser welding.

[0035] Furthermore, the housing 10 has two radially outwardly projecting ribs 17, which are set back from the opening 11 at a distance c and encircle the housing 10 at a distance a from each other. A circumferential groove is formed by the distance a. Preferably, the ribs 17 are equidistant from each other.

[0036] Furthermore, the lens 12 projects beyond an outer radial edge of the ribs 17 by a distance b. In this way, after the lighting device is installed in a motor vehicle, the ribs 17 remain hidden behind the lens 12, which contributes to an improved appearance of the motor vehicle. Reference numeral 2 in the figures indicates a rear section of the motor vehicle's body.

[0037] To separate the housing 10, it can be cut open between the ribs 17 in the area of ​​a separation line T using a suitable tool. The light lens 12, along with the attached housing part, can then be set aside. This separation creates an opening 11a (see figure). Fig. 2b), the exposure of which now provides good access to the circuit board 13 and the light sources 14, so that these can be replaced without hindrance.

[0038] After the repair, the housing 10 is reassembled with the previously separated ribs 17. For this purpose, a spacer 18 is inserted radially between the ribs 17 at several points. The spacer 18 preferably has a T-shaped cross-section, so that its T-legs abut the radial end faces of the ribs 17 and are securely adjusted. The spacer 18 can be fastened to the ribs 17 using an adhesive layer 19 or a screw connection 19'. A W-shaped cross-section for the spacer is also conceivable (not shown). In this case, a central web of the spacer can project between the ribs 17 and perform the spacer function, while two outer legs preferably spring against the ribs from the outside, thus providing a clamping hold.

[0039] When fastening by means of screws or clamps, a rubber seal can also be used instead of the adhesive layer. An internal separation joint F of the housing 10 remains. However, the housing 10 is sealed due to the measures mentioned above. The distance b of the lens 12 is dimensioned so that, even after the repair, the lens 12 still radially extends beyond the ribs 17 together with the spacers 18 (cf. Fig. 2b).

[0040] In the Fig. 3 and Fig. Figure 4 shows a lighting device 1b. In contrast to the previous lighting device 1a, this device has a light lens 12 which is detachably connected to the housing 10 at fastening points B. Preferably, the light lens 12 is detachably connected to the housing 10 via snap-fit ​​connections.

[0041] Specifically, such a snap-fit ​​connection can be configured as follows: the light lens 12 has a part 12a that extends beyond the housing 10, designed as a spring-loaded tab and provided with an opening 12b. Part 12a branches off from the edge of the light lens 12 to the rear, i.e., opposite the main emission direction HA. The housing 10, on the other hand, has two ribs 10a and 10b pointing in the main emission direction HA, between which a connecting web 10d is located, forming a distance d between the ribs 10a and 10b. The ribs 10a and 10b surround or define the opening 11 of the housing 10. The distance d between the ribs 10a and 10b forms a groove 10c between them. Here, too, the ribs 10a and 10b preferably run equidistant from each other.The groove 10c serves to receive a circumferential rib 23 projecting from the lens 12 in the opposite direction to the main emission direction HA. Furthermore, a sealing ring 20 is inserted in the groove 10c between the rib 23 and the housing 10. A resilient tab 10f projects rearward from the radially outer rib 10a of the housing 10 in the opposite direction to the main emission direction HA. The resilient tab 10f is provided at its free end with a radially outwardly projecting projection 10e. The projection 10e has a detent chamfer that rises towards the free end of the tab 10f.

[0042] For repair, refurbishment, or recycling, the lens 12 can now be easily detached from the housing 12 at the mounting points B. This is done by lifting the part 12a that extends over the housing 10 at its free end over the projection 10e at each mounting point B. The lens 12 then simply needs to be pulled off the housing 10. Due to the resulting unimpeded access, components located inside the housing 10 can be replaced or removed.

[0043] In this way, it is also conceivable to reuse the lens and housing if they are still intact and only the electronic interior of the lighting device is to be "modernized".

[0044] To reassemble the lighting device 1b, the lens 12 is pushed onto the spring-loaded tab 10f in the area of ​​the mounting points B, with the tab-like part 12a extending until the end of the tab-like part 12a reaches the detent chamfer of the projection 10e. Further pushing deflects the tab-like part 12a radially outwards, and it then springs radially inwards, engaging the projection 10e in the opening 12b. In this process, the web 23 also comes into contact with the sealing ring 20 located in the groove 10c, compressing it and creating a seal.

[0045] This solution also makes it clear that, due to the part 12a of the lens 12 extending beyond the housing 10, the method of fastening the lens 12 remains hidden from an observer as soon as the lighting device 1b is installed on a motor vehicle.

[0046] In contrast to the exemplary embodiment, it is also conceivable that only part of the detent components involved are resilient and the other part is rigid. For example, the part 12a of the lens 12 that overlaps the housing 10 can be resilient and the overlapping part of the housing 10 can be rigid. The reverse case and combinations thereof are also conceivable.

[0047] Based on the Fig. 5 and Fig. Section 6 describes an embodiment of a lighting device 1c in which the detachability of the light disc 12 is achieved in a different manner. In the lighting device 1c, the housing 10 also has two ribs 10a, 10b pointing in the main emission direction HA, which are spaced apart from each other by a connecting web 10d and form a groove 10c. The radially outer rib 10a, however, is only set back against the main emission direction HA by the connecting web 10d to such an extent that a groove 10g oriented against the main emission direction HA is formed. The light disc 12 also has a part 12a that overlaps the housing 10, or more precisely, the radially outer rib 10a. The part 12a, together with spaced-apart, radially outwardly pointing ribs 12c, forms an outwardly directed groove 12d.The groove 12d of the light disc 12 and the groove 10g of the housing 10 are arranged laterally offset from each other in a view in the main emission direction HA on the back of the lighting device 1c, thus alternating with each other.

[0048] The lens 12 is attached to the housing 10 by several mounting points B, each of which has a first mounting area B1 and a second mounting area B2. A wire-shaped, circumferential mounting element 21 is present, which meanders through the mounting points B. In mounting area B1, the mounting element 21 engages the groove 10g from the rear. In mounting area B2, the mounting element 21 engages the groove 12d from above. Since the grooves 10g and 12d are offset from each other, as described above, the mounting areas B1 and B2 are also offset from each other. The lens 12 is sealed by a rib 23, which engages in a groove 10c formed between the ribs 10a and 10b and interacts with a sealing ring 20 located there.

[0049] If the lens 12 is to be detached from the housing 10, it is sufficient to cut the wire-shaped, circumferential fastening element 21 at one point. This element can then be detached from all fastening points B. The lens 12 can then be easily removed, providing unimpeded access to the components located in the housing 10.

[0050] The components are assembled by sliding the lens 12 onto the housing 10 until part 12a of the lens 12 overlaps the housing 10 again and the web 23 projects into the groove 10c. Finally, a new fastening element 21 is clamped around the fastening points B such that the interaction of the web 23 and the sealing ring 20 ensures a seal.

[0051] Finally, the aim is to use the Fig. 7 and Fig. 8 Another embodiment of a lighting device 1d will be explained. In contrast to the embodiment according to the Fig. 3 and Fig. 4 is the web 23 of the light disc 12 projecting into the circumferential groove 10c of the housing 10, which is part of a first, frame-like part 12-1 of the light disc 12. The frame-like part 12-1 is made of a first, opaque material component, for example, a black plastic.

[0052] Within the first, frame-like part 12-1, a second part 12-2 of the light pane 12, made of a second, transparent material component, is arranged. The second, transparent material component can be colored, for example, red. The second part 12-2 of the light pane 12 is detachably attached to the inside of the first, frame-like part 12-1 of the light pane 12. A rib 23a of the first part 12-1 of the light pane 12, pointing in the opposite direction to the main emission direction HA, projects into a groove 12e of the second part 12-2 of the light pane 12 and seals against a sealing ring 20. At an edge region 12f of the second part 12-2 of the light pane 12, the second part 12-2 is attached to the inside of the first, frame-like part 12 of the light pane 12 by means of fasteners 22, preferably by screws.

[0053] Similarly, a further, third part 12-3 of the light disk 12 can be connected to the first, frame-like part 12-1. The third part 12-3 of the light disk 12 can be made of a third, also transparent, material component. The third material component can be colorless or colored, for example, orange.

[0054] Thus, for example, the first part 12-1 can provide a covering function for the mounting areas of the second and third parts 12-2 and 12-3, while the second part 12-2 can support the lighting function of a tail light or brake light and the third part 12-3 can support the lighting function of a reversing light or direction indicator.

[0055] Because the light disk 12 can be disassembled into its individual material components, a targeted repair of a damaged part of the light disk 12 can be carried out if necessary, or the material components can be separated by type at the end of the life cycle. Reference symbol list 1a-1d Lighting device 2 Bodywork 10 cases 10a rib 10b rib 10c Nut 10d connecting bridge 10 lead 10f spring-loaded tab 10g Nut 11 Opening 12 Light disc 12-1 first part of the light disc 12-2 second part of the light disc 12-3 third part of the light disc 12a the housing-spanning part of the light lens 12b Opening 12c rib 12d Nut 12e Nut 12f Edge area 13 circuit boards 14 light bulbs 15 Reflector 16 Bridge 17 ribs 18 spacers 19 adhesive layer 19' screw connection 20 sealing rings 21 Fastening element 22 Fasteners 23 Bridge 23a Footbridge a distance b distance c distance d distance B Fixing points B1 first area B2 second area F Separation joint HA Main beam direction K Contact surface L Light rays T dividing line

Claims

[1] Lighting device (1a, 1b, 1c, 1d) for a motor vehicle, comprising a housing (10), at least one light source (14) received in the housing (10) and a lens (12) which closes off an opening (11) of the housing (10) to the outside, characterized by , that the light disk (12) is inseparably connected in the area of ​​the opening (11) to a web (16) pointing towards the housing (10) on an end face contact surface (K) of the housing (10), wherein the housing (10) has two radially outwardly projecting ribs (17) which are set back from the opening (11) of the housing (10) and surround the housing (10) at a distance (a) from each other, wherein a circumferential groove is formed by the distance (a) and the light disk (12) projects radially beyond an outer edge of the ribs (17) at a distance (b) or characterized bythat the housing (10) has two ribs (10a, 10b) pointing in a main emission direction (HA) of the lighting device (1b), which surround or limit the opening (11) of the housing (10) and which extend at a distance from each other, wherein a circumferential groove (10c) is formed by the distance into which a circumferential web (16) of the light disk (12) projects, wherein the light disk (12) is detachably connected to the housing (10) at fastening points (B, B2) with a part (12a) that overlaps the housing (10) externally, wherein the part (12a) of the light disk (12) that overlaps the housing (10) forms a radially outwardly directed groove (12d) into which a fastening element (21) projects, wherein the fastening element (21) also extends at least into a groove formed on the housing (10) that is directed opposite to the main emission direction (HA). (10g) protrudes. [2] Lighting device (1c) according to claim 1, characterized by, that the groove (12d) on the part (12a) of the light disc (12) that overlaps the housing (10) and the groove (10g) formed on the housing (10) are arranged offset from each other along the circumference of the lighting device (1c), wherein the fastening element (21) is wire-like and circumferentially formed. [3] Lighting device (1b, 1c) according to one of the preceding claims, characterized by , that a sealing ring (20) is arranged in the circumferential groove (10c) into which the circumferential web (16) of the light disk (12) projects. [4] Method for repairing a lighting device (1a) according to the first alternative of claim 1, wherein the housing (10) is cut open between the radially outwardly projecting ribs (17) and, after the repair has been carried out, the ribs (17) are placed and fastened to spacers (18) inserted between them. [5] Method according to claim 4, characterized by, that the spacers (18) are fastened by an adhesive layer (19) acting on the spacer (18) and the ribs (17), by a clamping force acting on the ribs (17) or by a screw connection (19') acting on the spacer (18) and the ribs (17). [6] Method according to claim 5, characterized by , that a T-shaped or W-shaped spacer (18) in cross-section is used.