Dual-axis alignment for LED regulatory optics

Abstract

Vehicle light (1000), which includes the following: a substrate (1008); a lens (1002) wherein a lamp chamber (1022) is formed between the lens (1002) and the substrate (1008) to accommodate a light source (1024), wherein the lens (1002) has a horizontal axis (H) and a vertical axis (V), an alignment element (1014) which extends from the lens (1002) in at least three sections (1010) parallel to the substrate (1008), each of the three sections (1010) having an opening (1038) which is aligned with a corresponding opening (1028) in the substrate (1008); a two-axis adjustment mechanism (1030) comprising the following: three elements (1032, 1034, 1036), each element extending through the respective opening of one of the at least three sections (1010) and the corresponding opening in the substrate (1008), the three elements (1032, 1034, 1036) having the following: a fixed element (1032) which is fixedly connected to both the substrate (1008) and the alignment element (1014) and is arranged on both the horizontal (H) axis and the vertical (V) axis; a vertical adjustment device (1034) which is fixedly attached to the alignment element (1014) and movable with respect to the substrate (1008), wherein the vertical adjustment device (1034) is arranged on the horizontal axis (H) and is configured such that the lens (1002) can be adjusted with respect to the vertical axis (V); and a horizontal adjustment device (1036) which is fixedly attached to the alignment element (1014) and movable with respect to the substrate (1008), wherein the horizontal adjustment device (1036) is arranged along the vertical axis (V) and is configured such that the lens (1002) can be adjusted with respect to the horizontal axis (H); and a flexible skirt (1006) which frames a front surface (1004) of the lens (1002) from which light emerges without gaps, wherein the flexible skirt (1006) extends towards the substrate (1008) to enclose the lamp chamber (1022).

Description

TECHNICAL AREA

[0001] This disclosure relates to the area of ​​regulatory optics used in luminaires employed for illumination or signaling in applications such as vehicle headlights, taillights, signal lights, etc. The regulatory optics may be uniform structures made of optical silicone used with LEDs, or they may be lenses made of plastic, glass, or another transparent material to which a silicone or other elastomeric or flexible component is attached, such as a skirt, through which biaxial alignment is achieved. BACKGROUND

[0002] Optical lenses, which serve to focus and direct the light emitted by light sources, are manufactured using basic techniques to adjust the light output. Since the 1980s, plastic lenses have replaced glass as the transparent outer shell for lighting applications in most areas. Historically, plastic lenses were made from, but were not limited to, rigid materials such as polycarbonate (PC), polymethyl methacrylate (PMMA), polystyrene (PS), cyclic olefin polymers (COP), and cyclic olefin copolymers (COCP).

[0003] These materials are essentially rigid and do not deform significantly under pressure or gravity. Once properly fixed in place, such materials essentially retain their geometric shape. However, the use of plastics for optical lenses has many disadvantages, particularly in the automotive sector: they tend to deform or distort under heat, have low abrasion resistance and are therefore prone to scratches, and are susceptible to damage from UV (ultraviolet) radiation, such as discoloration. Furthermore, separate components (e.g., when using reflector optics) can lead to additional disadvantages and reduced efficiency. The need for weatherproof, lightweight lights for electric and autonomous vehicles that meet the diverse requirements of different applications while also complying with regulatory requirements is constantly growing.

[0004] Another disadvantage of conventional optical plastic lenses is the need for an adjustment mechanism to align the light(s) and compensate for variations in the vehicle's position relative to the road. A conventional light, for example, is attached to a vehicle using four protrusions, with three external adjustment devices located at the corresponding points on the light. These adjustment devices require installation space, increase the weight of the light, and take time to align correctly. Furthermore, each light must be a separate, individual unit, as the alignment is tied to the light housing.

[0005] US Patent 8,845,128 B2 discloses a vehicle headlight assembly comprising a lens, a lamp housing that interacts with the lens to define at least a portion of a lamp chamber, which is generally fluidically isolated from an ambient atmosphere outside the lamp chamber, and at least one lamp provided within the lamp chamber. The lamp housing includes at least one structural element designed to be connected to one or more adjacent components of a vehicle in which the vehicle headlight assembly is installed and to support structural loads applied by them.

[0006] An adjustable light fixture, in which an adjustment unit can pivot a light holder relative to a mounting base via a pivoting section, is described in US 11,788,700 B1. US 2008 / 0225,546 A1 describes a vehicle headlight that includes, among other things, a light source adjustment mechanism and a heat dissipation module. US 2017 / 0008,443 A1 relates to a mounting device for securing and aligning light modules used in a headlight. Lights with adjustment mechanisms are also described in US 2017 / 0043,706 A1, US 2018 / 0086,251 A1, and EP 2,719,941 A1. OVERVIEW

[0007] This document discloses embodiments of unified optically clear regulatory optics or lenses. An example of a unified regulatory optic such as disclosed herein has a shaped body comprising: a front surface configured as a light exit; an integral TIR (Total Internal Reflection) reflector configured to receive and reflect light from an LED light source; and an integral mounting section configured to secure the shaped body in a housing. "Unified" here means a single, uniformly shaped body.

[0008] Furthermore, luminaires, e.g., for vehicles, are disclosed here. An example of a luminaire has a uniformly shaped optic or lens comprising: a front surface configured as a light-emitting element; an integral reflector shaped to meet a prescribed light output; and an integral mounting section. The luminaire also includes an LED light source, wherein the integral reflector receives and reflects light from the LED light source, and a housing configured to allow the uniformly shaped body to be mounted in a structure, with the integral mounting section attached directly to the housing without an additional sealing element.

[0009] Another example of a luminaire with single-stage optics features a single, molded silicone body comprising: a front surface configured as a light-emitting surface; an integral reflector shaped to meet a prescribed light output; and an integral mounting section. The luminaire also includes a light source and a housing configured to allow the single-molded body to be attached to a structure.

[0010] The unified silicone regulatory optic disclosed herein provides a single-lens optic with an integrally molded reflector. The optic is molded from silicone and capable of complex regulations that meet the regulatory requirements for regulated lighting applications. The unified silicone regulatory optic offers a much lighter luminaire, which is advantageous for all vehicles, especially autonomous and electric vehicles. Because the optic is a single component, it can achieve an efficiency of 85%+, a significant improvement over conventional luminaires, which lose approximately 10% to 15% of light output for each optical component through which the light passes, such as a typical outer luminaire cover lens.Uniform silicone optics are particularly useful for LED applications because optical silicone has a significantly higher temperature resistance than conventional plastic lenses. This allows the optics to be placed in close proximity to, and even in contact with, the LED(s) without distortion or deformation. Furthermore, since optical silicone is virtually impervious to UV (ultraviolet) radiation, the close proximity of the optical silicone lens to the LED light source does not pose a risk of material degradation, such as yellowing, which can negatively affect plastic materials. The disclosed regulatory optics can be used without coatings or external lenses because the silicone is effectively resistant to UV damage and damage from road grime, although silicone coatings that further enhance performance are also possible.The regulatory optics revealed here can be installed directly into the vehicle light housing without the need for additional sealants or gaskets, as the silicone can also be configured as an effective seal. Since the optic is a single piece, no alignment between components is required during installation.

[0011] Also disclosed is a luminaire comprising: a lens having a front light-emitting surface, three alignment sections extending from at least three edge positions of the lens, a substrate arranged opposite the front light-emitting surface and positioned parallel to the three alignment sections, with a flexible material between the substrate and the three alignment sections, the substrate having three openings aligned to the three alignment sections; and a two-axis adjustment mechanism.The two-axis adjustment mechanism comprises the following: a fixed element that is rigidly connected to both the substrate and one of the three alignment sections and is positioned on both a horizontal axis and a vertical axis of the lens; a vertical adjustment device that is rigidly attached to a second of the three alignment sections and movable with respect to the substrate, wherein the vertical adjustment device is positioned on the horizontal axis and configured to allow the lens to be adjusted with respect to the vertical axis; and a horizontal adjustment device that is rigidly attached to a third of the three alignment sections and movable with respect to the substrate, wherein the horizontal adjustment device is positioned along the vertical axis and configured to allow the lens to be adjusted with respect to the horizontal axis.A flexible skirt seamlessly frames a front face of the lens where light exits, with the flexible skirt extending to the substrate to enclose the lamp chamber.

[0012] Also disclosed is a vehicle lamp comprising: a substrate, a lens, wherein a lamp chamber is formed between the lens and the substrate to accommodate a light source, the lens having a horizontal axis and a vertical axis, an alignment element integral with the lens and extending from the lens in at least three sections parallel to the substrate, each of the at least three sections having an opening aligned with a corresponding opening in the substrate, and a two-axis adjustment mechanism. The two-axis adjustment mechanism has three elements, each element extending through the respective opening of one of the three sections and the corresponding opening in the substrate.The three elements comprise the following: a fixed element that is rigidly connected to both the substrate and the alignment element and is arranged on both the horizontal and vertical axes; a vertical adjustment device that is rigidly connected to the alignment element and movable with respect to the substrate, wherein the vertical adjustment device is arranged on the horizontal axis and configured so that the lens can be adjusted with respect to the vertical axis; and a horizontal adjustment device that is rigidly connected to the alignment element and movable with respect to the substrate, wherein the horizontal adjustment device is arranged along the vertical axis and configured so that the lens can be adjusted with respect to the horizontal axis.A flexible skirt frames a front face of the lens, from which light exits, without gaps, with the flexible skirt extending to the substrate to enclose the lamp chamber.

[0013] Also disclosed is a vehicle light comprising: a uniformly shaped lens made of optical silicone having a vertical axis extending along a vertical edge and a horizontal axis extending along a horizontal edge, wherein the uniformly shaped lens comprises: a front surface configured as a light exit; an integral reflector adjacent to the front surface to meet a prescribed light output; and a reinforcement structure formed into the uniformly shaped lens to provide structural strength to the optical silicone, wherein the reinforcement structure has three alignment sections extending from the reinforcement structure, each of the three alignment sections having an alignment aperture.The vehicle lamp further comprises: a substrate forming a lamp chamber with the uniformly shaped lens in which a light source is housed, the substrate being parallel to the three alignment sections and having three substrate openings, each substrate opening being aligned with a corresponding alignment opening, and a two-axis adjustment mechanism. The two-axis adjustment mechanism has three elements, each element extending through the substrate opening that is aligned with the respective alignment opening.The three elements comprise: a fixed element that is rigidly connected to both the substrate and one of the three alignment sections and is positioned on both the horizontal and vertical axes; a vertical adjustment device that is rigidly attached to a second of the three alignment sections and movable with respect to the substrate, wherein the vertical adjustment device is positioned on the horizontal axis and configured to allow the uniformly shaped lens to be adjusted with respect to the vertical axis; and a horizontal adjustment device that is rigidly attached to a third of the three alignment sections and movable with respect to the substrate, wherein the horizontal adjustment device is positioned along the vertical axis and configured to allow the uniformly shaped lens to be adjusted with respect to the horizontal axis.A flexible skirt frames the front of the one-piece molded lens and extends to the substrate to form a gapless seal between the one-piece molded lens and the substrate, the flexible skirt being configured to maintain the gapless seal during alignment with the two-axis adjustment mechanism.

[0014] These and other embodiments and aspects are considered here. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The revelation is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, in accordance with common practice, the various features in the drawings are not to scale. On the contrary, the dimensions of the various features have been arbitrarily enlarged or reduced for clarity. Fig. 1A is a perspective front view of a uniform silicone regulatory appearance, as revealed here. Fig. 1B is a perspective rear view of the uniform silicone regulation optics made of Fig. 1A. Fig. 1C is a top view of the uniform silicone regulatory appearance made of Fig. 1A. Fig. 1D is a view from the right side of the uniform silicone regulatory optics. Fig. 1A. Fig. 1E is a rear perspective view of a cross-sectional view of the uniform silicone standard optics made of Fig. 1A along line E. Fig. 1F is a rear perspective view of a cross-sectional view of the uniform silicone standard optics made of Fig. 1A along line F. Fig. 1G is a top view of the uniform silicone regulatory optics made of Fig. 1E. Fig. 1H is a view from the right side of the uniform silicone regulatory optic in Fig. 1F. Fig. Figure 2 is a perspective front view of another aspect of a uniform silicone regulation optic, as revealed here. Fig. Figure 3 is a perspective front view of another aspect of a uniform silicone prescription optic disclosed herein, with heating and / or amplification embedded in the outer section of the lens unit. Fig. 4A is a perspective view of a luminaire with a single-stage optic, as revealed here. Fig. 4B is an exploded view of the light fixture. Fig. 4A. Fig. 5A is a perspective front view of a silicone regulation light fixture with single-point adjustment, as revealed herein, with a transparent skirt. Fig. Figure 5B is a perspective front view of a single-point adjustable silicone regulation light fixture, as revealed herein, with an opaque skirt. Fig. 6A is an enlarged section of a regulatory lamp showing an adjustment mechanism accessible from the front. Fig. 6B is an enlarged section of a perspective rear view of the regulation light fixture made of Fig. 6A, which shows the adjustment mechanism that is also accessible from the rear. Fig. Figure 7 is a perspective front view of a regulatory lamp disclosed herein, with the skirt removed to better highlight the components. Fig. 8A-8C are partial side views of the Fig. 7, which show the adjustment of the lens using the adjustment mechanism disclosed herein. Fig. Figure 9 is a perspective front view of another regulatory lamp disclosed herein, in which the skirt has been removed to better highlight the components. Fig. 10A is a perspective front view of a vehicle headlight as revealed here. Fig. 10B is a perspective rear view of the vehicle headlight from Fig. 10A. Fig. Figure 11A is a front view of a multi-element vehicle headlight and vehicle component as revealed here. Fig. 11B is a rear view of the multi-element vehicle headlight and a vehicle component made of Fig. 11A. Fig. Figure 12A is a perspective front view of a vehicle headlight and vehicle component as revealed here. Fig. 12B is a perspective rear view of the vehicle headlight and a vehicle component made of Fig. 12A. Fig. Figure 13 is a representation of a vehicle with a multi-element vehicle headlight disclosed herein. Fig. Figure 14 is a perspective front view of a vehicle light which has a two-axis adjustment mechanism described herein. Fig. Figure 15 is a perspective front view of another aspect of a vehicle light, which shows the two-axis adjustment mechanism described herein with a transparently depicted skirt. Fig. Figure 16 is a perspective rear view of the vehicle light. Fig. 14, with the substrate removed. Fig. Figure 17 is a rear view of another embodiment of a vehicle light which has a two-axis adjustment mechanism described herein. Fig. Figure 18 is a rear view of a substrate. Fig. 19 is a perspective front view of the Fig. 15, with the apron and substrate removed. Fig. 20 is a cross-sectional view from Fig. 15 along line 20. Fig. 21 is a cross-sectional view from Fig. 14 along line 21. Fig. 22 is a vehicle that has a vehicle light described herein with the two-axis adjustment mechanism. Fig. 23A and Fig. 23B represents conventional vehicle lights with conventional adjustment mechanisms that require a gap. DETAILED DESCRIPTION

[0016] Conventional automotive lights contain a light source, which may include a printed circuit board, a primary optical system, which may include a reflector and a separate lens, and secondary optics. The components are housed in a casing containing an outer lens to create a generally fluid-insulated system. In certain applications, such as fog lights, additional lenses, such as a collimating lens, may be included in the primary optics. Reflectors are typically manufactured from various plastics by injection molding, metal casting, or stamping. The outer lenses of the secondary optics are usually made of glass, but have evolved to include plastics such as PC, PMMA, PS, COP, and COCP. While glass is both weather- and UV-resistant, plastics generally are not.Therefore, external plastic lenses typically require a UV coating to protect against damage from sunlight, as well as a hard coating to protect against damage from road grime. To further protect the light from the elements, seals and / or sealants are necessary to properly seal the light, at least between the outer lens and the housing.

[0017] These conventional lights require multi-stage optics to properly collect the light and then direct it into the desired illumination pattern. As the light passes through multiple components, efficiency is lost. On average, about 10% to 15% efficiency is lost when the light is reflected or passes through each successive medium. The current efficiency of conventional automotive lights for optical reflector systems is around 40% or less, meaning that a significant portion of the LEDs' light output is lost.

[0018] This document describes embodiments of a one-stage optic used with a light source and a housing to provide a luminaire that, among other advantages, is lightweight, has fewer components, is waterproof, and UV-resistant. The uniform silicone regulation optics disclosed herein have a molded silicone body comprising: a front surface configured as a light-exit surface; an integral reflector configured to receive and reflect light from an LED light source; and integral mounting sections configured for mounting in a housing. The term "regulation" as used herein refers to an optic or lens designed to meet certain specifications regarding light or radiation pattern and intensity for a particular use of the optic.

[0019] The uniform silicone optics disclosed herein are understood by those skilled in the art to be used in numerous different applications, including those with regulated specifications and those without. Applications with regulated specifications, for example by a government or government agency, for which the disclosed optics are particularly suitable, include, without limitation, electric and motor vehicles (including automobiles, trucks, aircraft, watercraft, recreational vehicles, all-terrain vehicles, and the like), aerospace, and other lighting applications. Vehicle applications include, among others, headlights and taillights.The headlights and taillights described herein include turn signals, low beams, high beams, signal lights, side marker lights, auxiliary lights, rear lights, marker lights, position lights, brake lights, and fog lights. The term "vehicle exterior light" as used herein generally refers to the lights listed as well as other lights known and used in the industry. The standardized silicone optics can also be used in other industries and with other non-visible lighting features, such as LiDAR transmitters, infrared transmitters, radar transmitters, and LiFi (information / data transmission using light beams).

[0020] Optical silicone offers many advantages over the rigid plastic typically used for lenses. Ordinary plastic lenses for headlights, such as those made of PC (polycarbonate), require the additional application of external anti-UV coatings to prevent damage to the plastic, which otherwise quickly becomes opaque. This severely impairs functional performance and negatively affects the product's appearance. Such products typically have a limited lifespan, and prolonged exposure to sunlight (UV radiation) often leads to significant optical degradation, which is clearly detrimental for products that are frequently or constantly exposed to the sun. Optical silicone is resistant to damage from UV radiation. Tests with optical silicone have shown a resistance to UV damage of more than 10 years under direct sunlight. No anti-UV coating is required with optical silicone.

[0021] Conventional plastic lenses, especially those used in vehicle headlights, also require hard coatings to mitigate rapid surface degradation caused by impacts from foreign objects, such as those encountered while driving. Optical silicone is inherently resistant to impacts from pebbles and other road debris. The soft, rubbery properties of optical silicone are such that the energy does not penetrate and / or damage the surface of the plastic lenses, but is absorbed within the optical silicone without affecting the optical clarity of the material. The debris simply rebounds without damaging the optical silicone material.

[0022] Plastics used to manufacture lenses shrink upon cooling, resulting in a loss of critical optical shape definition as the material deviates from the desired optical geometry of the mold. This can be particularly pronounced in large molds, where large optical lens volumes lead to undesirable deformations in other critical optical areas. The industry has attempted to address such problems through multi-stage molding solutions, where the lenses are produced in successive "molding steps." In these subsequent processes, the material accumulates to control shrinkage and thus achieve accurate optical definition in the molded state. Such methods are inherently expensive due to the design of the molding equipment for multiple stages.

[0023] Optical silicone can be precisely molded into large-format optics with minimal sink marks or other optical defects in a single-step molding process. Optical silicone optics are formed through a chemical reaction process in which a base resin is typically mixed with a catalyst in a 50:50 ratio. Heat is applied to accelerate the chemical reaction and the curing process. Given the minimal, well-controlled shrinkage of the material compared to the significantly greater shrinkage of thermoplastics, far greater accuracy in replicating the optical surface is achieved, all in a single molding step.These properties are crucial for achieving sharp, knife-edge optical elements, which would otherwise be less precise, rounder, and less defined when using plastics, resulting in undesirable optical inaccuracies. Optical silicone is inherently rubbery. The flexibility of optical silicone allows for the creation of flexible elements, significant undercuts that would otherwise prevent plastics from being removed from the mold without modifications to the mold, and the ability to deform significantly and yet return to the shape into which it was molded. A key characteristic of silicone is its high degree of elasticity and shape memory, which allows for a high degree of deformation but also permits a return to the original, molded geometry once the external forces are removed.This stands in stark contrast to the rigid nature of plastics and optical elements made of glass.

[0024] While glass can produce razor-sharp edges, these are inherently extremely brittle and susceptible to damage from handling, impacts, or vibrations. Any such damage immediately leads to very negative optical effects, making the use of glass materials impractical for sharp-edged configurations. In contrast, optical silicone materials allow for the creation of very sharp, highly defined optical surfaces that are virtually impervious to handling, vibration, and even light exposure. Light exposure is readily absorbed, and the material's inherent memory ensures a return to its original geometry, thus maintaining optical function even under adverse, even extreme, operating conditions.

[0025] Another advantage of using optical silicone is its significantly higher temperature resistance compared to other common plastics used for optical applications. This makes optical silicone particularly attractive for LED applications where close proximity between the optical element and the LED source is functionally advantageous. Such proximity between LEDs and conventional plastic lenses is often not possible because, for example, plastic optics can be thermally damaged by high temperatures. Conventional clear plastics are only temperature-resistant up to about 100°C. PC, for instance, deforms at 120°C, and PMMA is only temperature-resistant up to about 90°C. Silicones are generally temperature-resistant up to around 200°C, which is almost twice as high as that of conventional optical plastics.High-performance LEDs, such as those developed for automotive headlights, typically have an outer surface temperature of around 135°C, which is well above the softening temperature of optical PC materials. Therefore, care must be taken to ensure that the plastic optical components are positioned a sufficient distance from the LED light sources to prevent deformation or even melting. Silicone optics can thus be placed near or directly above high-temperature LED light sources, significantly improving optical performance while simultaneously eliminating damage over time – a crucial functional advantage. Naturally, these uniform silicone regulatory optics can also be used with incandescent bulbs, halogen lamps, high-pressure discharge / xenon lamps, and projector units.

[0026] Another advantage of optical silicone relates to the previously mentioned tendency of PC to degrade under the influence of UV radiation, which is even emitted to a small extent by most LEDs. Over time, such UV radiation can negatively affect the color and transmittance of PC and other optically clear plastics, leading to additional design problems that impair optical performance in both the short and long term. Optical silicone allows UV radiation to pass through, thus preventing any changes to the molecular composition and / or properties of the material over time.

[0027] The ability to integrate the outer lens, some or all of the additional optical elements, and the reflector into a single housing, thus enabling complete optical management, also offers many advantages. The silicone optics require no additional lenses for protection or further light refraction and can be directly exposed to the atmosphere.

[0028] Fig. Figure 1A is a perspective front view of an embodiment of a single-stage optic or lens for a luminaire or a uniform silicone standard optic 100, and Fig. 1B is a perspective rear view of Fig. 1A. The front surface 102 is an exit surface through which light exits the optic. The front surface 102 can be smooth, or it can have vertical or horizontal grooves, such as the horizontal grooves 210 found in the uniform silicone standard optic of Fig. Figure 2 shows the front surface 102. It may have cushions or other contours required to achieve the necessary light distribution pattern and / or light intensity. The grooves, depressions, or other optical features are formed into the front surface 102 during the molding of the regulation optic 100. The front surface 102 is designed to conform to the regulation and specifications for which it is intended to be used. The front surface 102 is generally uncoated unless coatings are applied to further enhance the already high functionality of the optical silicone by improving chemical resistance, surface strength, and the like. A coating to protect against UV radiation or damage is generally not required because the silicone material is UV-resistant and generally resistant to damage from impacting dirt.

[0029] As in Fig. As can be seen in Figure 1B, the reflector 104 is integrally formed with the front surface 102. The reflector 104 is configured to receive and reflect light from an LED light source 112, shown with a dashed line. The reflector 104 has one or more light-receiving surfaces 106, which are surfaces shaped around vertical and horizontal axes. The reflector 104 also has several reflective surfaces 108. Fig. 1D is a side view of the uniform silicone standard optic 100. Fig. 1E is a perspective view of a cross-section from Fig. 1B along line E, and Fig. 1F is a perspective view of another cross-section from Fig. 1B along line F. Fig. 1G is a top view of Fig. 1E, and Fig. 1H is a view from the right side of Fig. 1F when viewed from the front. Fig. 1G and Fig. Figure 1H shows the multiple light-reflecting surfaces 108. These multiple light-reflecting surfaces 108, which represent TIR (Total Internal Reflection) surfaces, focus the light and enable an efficiency of over 85%. The reflector 104, which works in conjunction with the light-emitting surface, the front 102, is shaped according to regulations, applications, and specifications. The reflector shown here serves as an example and is not to be understood as a limitation.

[0030] The uniform silicone regulatory optic 100 also has integral mounting sections 110 that will hold the uniform silicone regulatory optic 100 in a housing or support element. Due to the rubber-like, flexible nature of the optical silicone, the uniform silicone regulatory optic 100 can act as its own seal to create a tight seal with the housing. Conventional rigid plastics require the use of a gasket and / or sealant between the lens and the housing to protect the interior from moisture, such as rain, snow, and humidity, which can lead to moisture accumulation inside the luminaire or otherwise cause condensation on the inside of the lens.Such a gasket or other additional sealing element is not required, as the contact between the housing and the appropriately configured uniform silicone optic 100 is such that it seals against the elements without the need for a gasket or other additional sealing element. A simple mechanical retainer can be used to create a watertight contact between the silicone optic and the housing, ensuring a uniform and tight seal.

[0031] The rubber-like flexibility of optical silicone makes thin lenses or thin sections of lenses susceptible to deformation by external forces such as gravity, external mechanical pressure, aerodynamic pressure, vibrations, etc. Although the integral combination of the lens and reflector in the disclosed unified prescription optics generally results in a structure that is sufficiently thick and therefore not affected by the rubber-like flexibility with respect to deformation, some parts of the disclosed unified prescription optics may be thin enough to be affected. Accordingly, internal mechanical reinforcement in the thin sections may be desirable.

[0032] Fig. Figure 3 shows another aspect of a uniform silicone prescription optic 300. As shown, the uniform optic 300 is thicker where the lens or front surface 302 and the reflector 304 are formed, and thinner at the mounting sections 310. To provide structural mechanical strength to the mounting sections 310, a reinforcing structure 320, such as a reinforcing grid, is molded into the silicone material of the mounting sections 310. The uniform prescription optic 300 is internally reinforced at the mounting sections 310 by the suitably mechanically strong reinforcing structure 320 as well as by the thickness of the rest of the optic. The reinforcing structures 320 can be designed to provide sufficient structural reinforcement for the optic and may be selected for aesthetic or other reasons. The reinforcing structure 320 can be made of a variety of known materials, such as…thin wires, molded plastics, cast or formed metals, stamped metal parts, and the like. The reinforcement structure 320 is not limited to the mounting sections 310. The lens itself may be so thin that it deforms mechanically under normal operating conditions, e.g., due to vibration, mechanical pressure, aerodynamic loads, or even gravity, since optical silicone is very flexible due to its rubber-like properties. An internal mechanical reinforcement can be cast into the lens to mechanically stabilize it. This reinforcement device can also function as a heating mechanism by configuring these reinforcements to perform a heating function, e.g., by applying an electric current to the entire reinforcement grid or sections thereof.The amplification structures can be designed so that they do not interfere with the light pattern produced by the lens and / or the reflector.

[0033] Furthermore, luminaires with single-stage optics, e.g., for automotive applications, are described here. An example of a luminaire for a vehicle with single-stage optics is shown in Fig. 4A and Fig. 4B is shown, where Fig. 4B an exploded view of Fig. 4A is. The lamp 400 has a uniformly shaped body 402, which is molded from silicone. The uniformly shaped body 402 has a round cross-section and differs from the bodies shown in the other drawings to give an example of a different shape and specification. It should be noted that the uniformly shaped body can have any cross-sectional shape required for the construction of the lamp so that it engages with the housing. The uniform front surface and the reflector can be designed differently depending on the specification. In Fig. 4 The uniformly shaped body has a front surface 404 designed as a light outlet, an integrally molded reflector 406 which, in conjunction with the front surface 404, fulfills a prescribed light output, and an integral mounting section 408. As shown, the mounting section 408 has a first mounting element 410 and a second mounting element 412. The mounting section 408 can have any configuration that allows the required attachment to the housing and creates a watertight seal without the need for an additional sealing element, such as a gasket, although this does not preclude the use of adhesives or other fasteners if desired. The mounting section 408 in Fig. Section 4 comprises the first fastening element 410, which fits into a housing 420, and the second fastening element 412, which contacts the housing in a flange-like manner. Either the first fastening element 410 or the second fastening element 412, or both, may have a reinforcing structure, as previously described.

[0034] The luminaire 400 also includes an LED light source 430, with the integrated reflector receiving and reflecting the light from the LED light source 430. The LED light source is not limited and can consist of one or more LEDs and may include a circuit board and / or other means for powering and controlling the LED(s). A housing 420 is configured to seal and enclose the uniformly shaped body 402 and to mount the uniformly shaped body 402 on the exterior of a vehicle, with the integral mounting section 408 attached directly to the housing 420 without an additional sealing element. The housing 420 includes a single-stage lens mount 422 configured to attach to the uniformly shaped body 402, mounting elements 424 for attaching the luminaire 400 to a vehicle or other lighting application, and optionally a heat sink 426.The heat sink 426 can also be provided on the LED light source, or alternatively.

[0035] The unified silicone regulatory optics disclosed here offer a single-stage optic with an integrally molded reflector. The optics are molded from silicone and capable of complex regulations that meet the regulatory requirements for regulated lighting applications, either individually or in conjunction with one or more additional light units appropriately configured to achieve the desired overall optical radiation pattern results. The unified silicone regulatory optics provide a much lighter luminaire, which is advantageous for all vehicles, especially autonomous and electric vehicles. Because the optics are a single component, they can achieve efficiencies exceeding 85%, a significant improvement over conventional luminaires, which lose approximately 10 to 15% efficiency for each optical component through which the light passes or is reflected.The uniform silicone regulatory optics can be used with high-power LEDs because silicone has a higher temperature resistance than conventional plastic lenses. The disclosed regulatory optics are used without coatings or external lenses because the silicone is effectively resistant to UV damage and most damage from road grime, although additional coatings can be used to meet even higher requirements for robustness and chemical resistance. The disclosed regulatory optics can be installed directly into the vehicle's light housing without the need for an additional element such as a gasket, as the silicone acts as a seal, protecting the optics from weather-related problems such as the ingress of liquids, dust, or other contaminants.An adhesive or mechanical fastener can be used to achieve a uniform, secure fit between the housing and the optics. Since the optics are a single piece, no alignment between the components is required during installation in the application.

[0036] The use of silicone enables single-point adjustment of the prescription optics. The single-point adjustment mechanism can be used with both the prescription optics disclosed herein and with conventional plastic or glass lenses, provided that, in the case of conventional plastic lenses, a section of the lens is coated or molded with a compliant material such as rubber or silicone, and that this section is the section through which the adjustment mechanism extends.

[0037] Fig. 5A is a perspective view of a regulatory luminaire 500 with a single-point adjustment mechanism 550. Fig. 5A is shown with a substrate 502 and a transparent skirt 506 which is in contact with the substrate 502. Fig. 5B is a perspective view of the regulation luminaire 500' with an opaque skirt 506', mounted on the support 502. In the Fig. 5A and Fig. In 5B, the single-point adjustment mechanism 550 is only accessible from one side of the substrate 502. Fig. 6A and Fig. Figure 6B shows enlarged views of a regulatory lamp 600 with a single-point adjustment mechanism 650, which is accessible from the front 604, through the skirt 606, as well as from the heat sink side 602.

[0038] In the Fig. The single-point adjustment mechanism 650 is described in sections 7 and 8A-8C. Fig. Figure 7 shows the regulatory luminaire 600 with the compliant skirt 606 removed. The regulatory luminaire 600 has a regulatory optic 610, as disclosed herein. The regulatory optic 610 is a uniformly shaped body molded from silicone and comprises a front surface 612 configured as a light output, an integral reflector 614 shaped to meet a prescribed light output, an integral mounting section 616, and a reinforcing structure 618 formed with the uniformly shaped body, the reinforcing structure 618 providing structural strength to the mounting section 616. An LED light source is included (not shown), the integral reflector 614 receiving and reflecting light from the LED light source. The LED light source may consist of one or more types of LEDs and may include one or more LED circuit boards. A substrate 622 supports the LED light source.The substrate 622 can be a supporting structure on which the LED light source and the regulatory optics 610 can be mounted, or additionally a heat sink for the LED light source. A pivoting mechanism 624 extends from the substrate 622 and has opposing pivot points 626, with the reinforcement structure 618 pivotally attached to the opposing pivot points 626. The mounting section 616 includes an alignment section 620 that extends integrally from the mounting section 616 parallel to the substrate 622. The adjustment mechanism 650 extends through an opening 652 in the alignment section 610 of the reinforcement structure 618 at a location where the reinforcement structure 618 is covered by the flexible skirt 606.The flexible skirt 606 is a cover that fits around the front surface 612 of the optic 610 and is attached to the substrate 622 to cover and protect the mounting and alignment structures of the luminaire 600. The front surface 612 is exposed to the atmosphere, as the silicone lens does not require any additional lenses or covers to protect it from the atmosphere, as previously described.

[0039] The single-point adjustment mechanism 650 can be a rotatable mechanism accessible from the front of the luminaire 600, outside the apron 606, or from the rear of the luminaire 600, outside the substrate 622, or from both the front and rear of the luminaire 600. As a non-limiting example, the adjustment mechanism 650 can be a screw that is screwed to the single point 652 of the reinforcing structure 618. To be accessible from both the front and rear of the luminaire 600, the screw would be, as shown in Fig. 6A shown, outside the apron 606 and, as in Fig. 6B shows the extension through the substrate 622. The end of the adjustment mechanism 650 accessible from the substrate 622 can be flush with the substrate 622, as shown in the Fig. Figures 8A-8C illustrate this. The adjustment mechanism 650 can only be screwed into the reinforcement structure 618 at its interface with the opening 652 in order to move the reinforcement structure 618, and thus the regulatory optics 610, relative to the pivot points 626. As a non-restrictive alternative, the adjustment mechanism 650 can be fixed to the reinforcement structure 618 at the opening 652 by means of adhesive or flanges on both sides of the reinforcement structure 618 and then screwed to the substrate 622 through the substrate opening 630. Any configuration is acceptable as long as the adjustment mechanism 650 is configured to move and fix the reinforcement structure 618, and thus the regulatory optics 610, relative to the pivot points 626.

[0040] Fig. Figure 8A shows a neutral position of the regulatory optic 610 without any degree of inclination with respect to the substrate 622. When the adjustment mechanism 650 is rotated in one direction, the reinforcement structure 618 moves in a first direction with respect to the pivot points 626, thereby moving the entire silicon optic 610, which is formed with the reinforcement structure 618, around the pivot mechanism 624 or the focal point in the first direction, as shown in Fig. 8B. By rotating the adjustment mechanism 650 in the other direction, the entire reinforcement structure 618 with the integral silicone regulatory optics 610 is moved around the pivoting mechanism 654 in a second, opposite direction, as shown in Fig. 8C is shown. The movement required to align the light is small, usually about 4° in each direction.

[0041] The single-point adjustment mechanism 550, 650 works with the reinforced silicone optics because silicone is flexible. The silicone compresses or expands when the reinforced structure is tightened or loosened against the heat sink via the adjustment mechanism, thus moving the silicone optics around the focal point or axis of the pivot points. This is because the reinforcement structure extends across the entire mounting section of the uniformly shaped body and is attached at the opposing pivot points. With a plastic lens or optics, there is no flexibility for the adjustment mechanism to act upon, thus precluding this type of adjustability.It is conceivable that a lens made of plastic, glass, or another transparent material could be used with the single-point adjustment mechanism if at least at the adjustment point and at least between the lens and the substrate or heat sink, a cover or overmold made of silicone, rubber, or another flexible material is present. This would allow the lens, made of plastic, glass, or another suitable material, to move around the pivot point when the adjustment mechanism is rotated, with the cover either being compressed or expanding. As with the 600' lamp in... Fig. As shown in Figure 9, since no reinforcement structure is required for the optic 610' made of a suitable material other than silicone, the opening 652' through which the single-point adjustment mechanism 650' extends is located in an alignment section 620' of the mounting section 616' of the silicone-free optic 610', both of which are also made of the suitable silicone-free material. The mounting section 616' is also directly connected to the pivoting mechanism 624'. To enable the low degree of alignment required, the alignment section 620' of the glass or plastic prescription optic 610' is coated with a flexible material 630', such as silicone or rubber, between the alignment section 620' and the substrate 622'.The provision of the flexible material 630' between the rigid alignment section 620' made of glass, plastic or another suitable material and the substrate 622' enables the small degree of movement required for the alignment of the regulatory optics 610'.

[0042] Fig. 10A and Fig. Figure 10B shows a regulation luminaire 700 with a housing 702. In Fig. 10A the housing 702 adapts to the apron 704 of the silicone look 710. Fig. Figure 10B shows the substrate 706 as a heat sink, in this case with fins to increase the surface area and improve cooling. Four mounting elements 708 are shown for attaching the optical module to the housing 702. The single-point adjustment mechanism 750 is accessible from the heat sink side of the luminaire. The housing 702 can be attached to the substrate 706 by any acceptable means such as adhesive, clamps, etc.

[0043] It is also noted that the single-point adjustment mechanism can be used with a structural headlamp as disclosed in U.S. Patent 8,845,128 entitled "Structural Headlamp Assemblies for Vehicular Applications," which is incorporated herein by reference. The Fig. The internally adjustable modules shown in sections 5 to 8 can be mounted using the structural element. The structural element becomes the housing of the luminaire. As shown in the Fig. 11A and Fig. As shown in Figure 11B, a vehicle headlight and component assembly 800 can comprise one or more lenses, this example showing three lamps 802, a vehicle structural element 804 as a lamp housing which interacts with the lamp 802 to define at least a portion of a lamp chamber which is generally aerodynamically isolated from an ambient atmosphere outside the lamp chamber, at least one light source provided in the lamp chamber, a substrate 806 which is shown here as a finned heat sink to increase the surface area and improve cooling, wherein the substrate 806 supports the light source and the lens is pivotably attached to the substrate 806 as previously described. The vehicle structural element 804 is configured to support structural loads applied by a vehicle component. A single-point adjustment mechanism 850 is arranged through an adjustment section of the lens.The substrate 806, which carries the skirt, the regulation optics, the light source, and the adjustment mechanism, is attached to the structural element 804 of the vehicle by means of fasteners 810, to give a non-limiting example. It is noted that each lamp 802 is individually adjusted by its respective adjustment mechanism 850. The lamp 802 may have integral silicone regulation optics with a reinforcing structure and a skirt, as disclosed herein, or be made of plastic, glass, or another suitable material, provided that the lens is covered with silicone or rubber or the like between the alignment section and the substrate at the adjustment point, the lens being mounted over the pivot point. Fig. 12A and Fig. Figure 12B shows a vehicle headlight and component assembly 900, as used in the Fig. 11A and Fig. 11B is described, but with five individual lights and a non-linear formation configured to provide enhanced lateral illumination, such as the function of a cornering light or another similarly configured function. The vehicle headlight and component assembly 900 also includes a vehicle structural element 904.

[0044] The vehicle structural element 804, 904 can be an external structure of a vehicle, such as an outer panel, a fender, a bumper, a reinforcement, a shield, etc. The vehicle structural element, such as the light housing, is configured to bear a load from a vehicle component, which, as non-limiting examples, can be an inner fender bracket, a radiator bracket / module, a vehicle structural element, a battery box, an electronic control module, a snowplow support structure, and a reinforcement structure. Fig. Figure 13 is a clear example of a vehicle headlight and component assembly 800, 900, as shown in the Fig. 11A and Fig. 11B and Fig. 12A and Fig. 12B described, wherein the vehicle structural element 804, 904 is a front fender or bumper 950 of the vehicle 960.

[0045] The Fig. Figures 14-19 show embodiments of a lamp with a two-axis adjustment mechanism that allows the lens to be adapted to the requirements both during and after vehicle assembly, without requiring a gap around the lens to allow movement. Fig. 14, Fig. 16 and Fig. 19. The two-axis adjustment mechanism is only accessible from the back of the substrate. In the Fig. 15, Fig. 17 and Fig. 18 The two-axis adjustment is accessible from both the rear of the substrate and the front of the compliant skirt. Apart from accessibility, the embodiments are implemented in the same way.

[0046] Fig. Figure 14 is a perspective front view of a vehicle lamp 1000, which has a lens 1002 with a front light-emitting surface 1004. A compliant skirt 1006 frames the front light-emitting surface 1004 and extends to a substrate 1008, as best shown in the Fig. 16, Fig. 18 and Fig. Figure 19 shows how to seal the vehicle light without gaps. Fig. Figure 15 shows a vehicle light 1000 in which the flexible skirt 1006 is transparent so that the internal components can be described. Fig. 17 corresponds Fig. 15, wherein the flexible skirt 1006 and the substrate 1008 are removed. The vehicle light 1000 also has at least three alignment sections 1010, the at least three alignment sections 1010 extending from three edge positions 1016 of the lens 1002, the alignment sections 1010 being parallel to the substrate 1008. As shown in the figures, there are four alignment sections 1010, one extending from each edge position 1016 of the lens 1002. Although the two-axis adjustment mechanism uses only three alignment sections 1010, the vehicle lights 1000 are typically manufactured with four, one of which remains unused. This allows the vehicle light 1000 with the two-axis adjustment mechanism to be used on either the right or left side of the vehicle, with the three alignment sections 1010 being selected for use in the two-axis adjustment mechanism depending on the side.Of course, it is also possible that a vehicle light is manufactured specifically for a right or left side and therefore only has three alignment sections, all of which are used for the two-axis adjustment mechanism.

[0047] If the lens 1002 is made of conventional plastic or glass, the alignment sections 1010 can also be made of plastic or glass and be integrally formed with and extending from the lens 1002. Due to the rigid nature of the plastic or glass, a flexible material is placed between the substrate 1008 and the at least three alignment sections 1010. The flexible material accommodates the small changes (+ / - 4°) in alignment required by the two-axis adjustment mechanism.If the lens 1002, as disclosed with respect to the embodiments with single-point alignment, is a single-piece molded lens made of optical silicone having a front light-exiting surface 1004 and an integral reflector 1012 adjacent to the front light-exiting surface 1004, an alignment element 1014 made of a rigid material can be used, the optical silicone being molded over the alignment element 1014. The alignment sections 1010 extend from the alignment element 1014 and are also cast into the optical silicone. The alignment element 1014 can extend, as shown, along vertical sides or edges 1017 of the lens 1002. When used with the optical silicone, the alignment element 1014 is a reinforcing structure cast into the single-piece molded lens 1002 to impart structural strength to the optical silicone.When used as a reinforcement structure, the alignment element 1014 may also have additional support structures 1018, for example, along the lower or upper edges 1020 of the lens 1002, as long as the reinforcement structure does not interfere with the front light-exiting surface 1004. If the lens 1002 is round or oval, the alignment element may reinforce the lens by extending around its entire circumference or only along arcs on either side of the lens 1002. The flexible skirt would also be round or oval and would provide a gapless seal between the lens and the substrate.

[0048] In the vehicle light 1000, the substrate 1008 is also arranged at the rear of the light opposite the front light emission surface 1004, in order to enclose the vehicle light 1000 with the flexible skirt 1006 and the front light emission surface 1004. The substrate 1008 and the lens 1002 define a lamp chamber 1022 between the lens 1002 and the substrate 1008 to accommodate a light source 1024, such as an LED. The light source 1024 can be arranged directly on the substrate 1008 or on an optionally placed circuit board 1026. The substrate 1008 can be a heat sink exposed to the ambient atmosphere outside the lamp chamber 1022, so that heat from the light source 1024 is transferred to the ambient atmosphere.

[0049] The lens 1002 has a vertical axis V parallel to a vertical edge 1017 and a horizontal axis H parallel to a lower or upper edge 1020 of the lens, as shown in Figure 16, where the substrate has been removed to show the internals. The vertical axis V can extend along any vertical edge of the lens 1002 and be at a distance D from the actual vertical edge 1017 of the lens 1002, as shown in Figure 16. The vertical axis V can also extend directly along the vertical edge 1017 of the lens 1002, as shown in Figure 16. Fig. Figure 17 shows that the horizontal axis H can be aligned with or at a distance from a lower or upper edge 1020 of the lens 1002. The same applies if the lens is round or oval, with the vertical edge being the midpoint of the circumference furthest to the right or left, and the lower or upper edge being the midpoint of the circumference located at the top or bottom of the circumference.

[0050] The three alignment sections 1010 extend from the plastic / glass lens or the alignment element 1014 so that they run parallel to the substrate 1008, but at an equal distance from the substrate 1008. The flexible material with the glass / plastic lens is positioned between the three alignment sections 1010 and the substrate 1008 and can extend completely between the substrate 1008 and the three alignment sections 1010. In the case of alignment sections 1010 overmolded with optical silicone, the optical silicone is also located between the alignment sections 1010 and the substrate 1008.

[0051] The substrate 1008, which is in Fig. As shown in Figure 18 from the rear, the lamp can have three openings 1028 aligned with the three alignment sections 1010. As mentioned previously, the lamps can be manufactured for both sides and have four openings in the substrate aligned with the four alignment sections, although only three of the four are used for adjustment. A two-axis adjustment mechanism 1030 extends through the openings 1028 in the substrate 1008 and is attached to the respective alignment section 1010, as shown in the Fig. 15, Fig. 20 and Fig. Figure 21 shows that the two-axis adjustment mechanism 1030 has three elements, each element extending through a respective opening 1028 in the substrate 1008 and attached to a correspondingly aligned alignment section 1010. The three elements comprise: a fixed element 1032, which is fixedly connected to the substrate 1008 and to one of the three alignment sections 1010 and is arranged on both the horizontal axis H and the vertical axis V of the lens 1002; a vertical adjustment device 1034, which is fixedly attached to the second of the three alignment sections 1010 and is movable with respect to the substrate 1008, the vertical adjustment device 1034 being positioned on the horizontal axis H and configured to adjust the lens 1002 with respect to the vertical axis V.A horizontal adjustment device 1036 is fixedly attached to the third of the three alignment sections 1010 and is movable with respect to the substrate 1008, wherein the horizontal adjustment device 1036 is positioned along the vertical axis V and is configured to adjust the lens 1002 with respect to the horizontal axis H.

[0052] As already mentioned, the three elements 1032, 1034, 1036 of the two-axis adjustment mechanism 1030 can protrude through the flexible skirt to be accessible from the front of the lamp 1000, as shown in Fig. 20. The three elements 1032, 1034, 1036 can be rigidly connected to a corresponding alignment section 1010. Alternatively, the alignment sections 1010 can be, as shown in Fig. Figure 21 shows a corresponding opening 1038 through which the three elements 1032, 1034, and 1036 extend. The three elements are fixedly attached to the alignment sections through the openings 1038. The vertical adjustment device 1034 and the horizontal adjustment device 1036 are movable relative to the substrate 1008. They can be frictionally fitted through the openings 1028 so that they do not move freely but can be rotated by a person or a tool. The vertical adjustment device 1034 and the horizontal adjustment device 1036 can be screwed into the substrate 1008 through the openings 1028, as shown in Figure 21. Fig. Figure 19 shows that other means can also be used to achieve movement of the alignment sections 1010 by moving the vertical adjustment device 1034 and the horizontal adjustment device 1036 relative to the substrate 1008.

[0053] The vehicle light 1000, as revealed here, can be any type of headlight or taillight. The vehicle light 1000 can be mounted on a vehicle structural element configured to bear a load from a vehicle component, with the vehicle structural element and the flexible skirt forming a gapless seal. The vehicle structural element can either cover the flexible skirt 1006, so that only the front light-emitting surface 1004 of the lens 1002 is visible, or it can expose the flexible skirt 1006. The vehicle structural element can be an exterior panel, a fender, a bumper, or any other exterior vehicle component. Fig. 22 is a clear example of a vehicle light 1000, as it relates to the Fig. 14-21 is described, wherein the vehicle structural element 804, 904 is a front fender or a bumper 950 of the vehicle 2000. In Fig. 22 the flexible skirt 1006 together with the front light emission surface 1004 of the lens 1002 is exposed to the atmosphere.

[0054] The lights are positioned during vehicle assembly. This means that while the lights are normally preset at the supplier's factory, final adjustment is necessary at the end of the assembly line due to variations in vehicle construction. Only lamps specifically marked as such may be adjusted on-site so that the headlight can be fine-tuned for its final alignment in the vehicle.

[0055] A conventional headlight 10 is in the Fig. 23A and Fig. Figure 23B shows the alignment mounting parts 12 of the conventional lamp 10 extending from outside the lamp chamber. The adjustment mechanisms 14 are attached to a surrounding rigid environment 16, which is separated from the front surface 18 of the lens by a gap 20 that surrounds the entire front surface 18. This is necessary to allow the lamp to adjust and swivel freely. This gap is unsightly and provides a pathway for dust and dirt. The gap also provides a pathway for wind ingress, which can contribute to noise and negative aerodynamic properties. The lamp and the surrounding rigid environment are usually housed in a casing so that the gap is not visible when looking at the vehicle. This casing is then mounted on the vehicle, typically with some kind of bezel to improve the aesthetics of the casing.

[0056] The flexible, compliant skirt 1006 of the vehicle lights 1000 frames the front light-emitting surface 1004 of the lens 1002, the flexible skirt 1006 extending to the substrate 1008 and completely enclosing the lamp chamber 1022. The flexible skirt 1006 can be made of a transparent or an opaque material. In one aspect, the flexible skirt 1006 is made of silicone, which provides a gap-free seal with the lens 1002 and is configured such that the gap-free seal is maintained during adjustment with the two-axis adjustment mechanism 1030. Because of this seal, the lights 1000 disclosed herein do not require a housing to cover the flexible skirt 1006 and the lens 1002. Instead, the flexible skirt 1006 and the lens 1002 can be directly exposed to the atmosphere outside the vehicle.If the lens 1002 is made of silicone, it does not require any further coating, as silicone is UV-resistant and resistant to dents and dirt. This is in . Fig. Figure 22 illustrates this. Due to the tight, gap-free seal between the flexible skirt 1006, the lens 1002, and the substrate 1008, there are no gaps, preventing the ingress of dust and dirt. The gap-free seal also prevents wind ingress, which can contribute to noise generation and negative aerodynamic properties.

[0057] The 1000 lamps disclosed herein can be used with Advanced Front Lighting Systems (AFS). With AFS, the lens moves from left to right when the steering wheel is turned. As in Fig.As shown in Figure 20, a stepper motor 1050 can be connected to the vertical adjustment device 1034 to dynamically adjust the lens 1002 laterally around the vertical axis. The stepper motor 1050, or another stepper motor, can additionally or alternatively be connected to the horizontal adjustment device 1036 and used to dynamically adjust the lens 1002 up and down around the horizontal axis.

[0058] Although the disclosure has been described in connection with certain embodiments, it is to be understood that the disclosure is not limited to the disclosed embodiments, but on the contrary is intended to cover various modifications and equivalent arrangements that fall within the scope of the attached claims, the scope being to be interpreted as broadly as possible to include all legally permissible modifications and equivalent structures.

Claims

[1] Vehicle light (1000) comprising the following: a substrate (1008); a lens (1002) wherein a lamp chamber (1022) is formed between the lens (1002) and the substrate (1008) to accommodate a light source (1024), wherein the lens (1002) has a horizontal axis (H) and a vertical axis (V), an alignment element (1014) which extends from the lens (1002) in at least three sections (1010) parallel to the substrate (1008), each of the three sections (1010) having an opening (1038) which is aligned with a corresponding opening (1028) in the substrate (1008); a two-axis adjustment mechanism (1030) comprising the following: three elements (1032, 1034, 1036), each element extending through the respective opening of one of the at least three sections (1010) and the corresponding opening in the substrate (1008), the three elements (1032, 1034, 1036) having the following: a fixed element (1032) which is fixedly connected to both the substrate (1008) and the alignment element (1014) and is arranged on both the horizontal (H) axis and the vertical (V) axis; a vertical adjustment device (1034) which is fixedly attached to the alignment element (1014) and movable with respect to the substrate (1008), wherein the vertical adjustment device (1034) is arranged on the horizontal axis (H) and is configured such that the lens (1002) can be adjusted with respect to the vertical axis (V); and a horizontal adjustment device (1036) which is fixedly attached to the alignment element (1014) and movable with respect to the substrate (1008), wherein the horizontal adjustment device (1036) is arranged along the vertical axis (V) and is configured such that the lens (1002) can be adjusted with respect to the horizontal axis (H); and a flexible skirt (1006) which frames a front surface (1004) of the lens (1002) from which light emerges without gaps, wherein the flexible skirt (1006) extends towards the substrate (1008) to enclose the lamp chamber (1022). [2] Vehicle light (1000) according to claim 1, wherein: the alignment element (1014) extends along vertical sides of the lens (1002); the lens (1002) is made of silicone; and the silicone covers the alignment element (1014) including the at least three sections (1010). [3] Vehicle light (1000) according to claim 1, wherein the lens (1002) is made of a material other than silicone and the at least three sections (1010) of the alignment element (1014) have a flexible material between each of the at least three sections (1010) and the substrate (1008). [4] Vehicle lamp (1000) according to claim 1, wherein the substrate (1008) is a heat sink which is exposed to the ambient atmosphere outside the lamp chamber (1022) so that heat is transferred from the light source (1024) to the ambient atmosphere. [5] Vehicle light (1000) according to claim 1, wherein the flexible skirt (1006) is made of silicone. [6] Vehicle light (1000) according to claim 1, wherein the flexible skirt (1006) is made of a transparent or opaque material. [7] Vehicle light (1000) according to claim 1, wherein the flexible skirt (1006) is made of silicone and is configured to maintain a gap-free seal during adjustment by means of the two-axis adjustment mechanism (1030). [8] Vehicle lamp (1000) according to claim 1, wherein the three elements (1032, 1034, 1036) of the two-axis adjustment mechanism (1030) extend through a surface of the compliant skirt (1006), making adjustment possible from a front of the vehicle lamp (1000). [9] Vehicle light (1000) according to claim 1, which further comprises a bracket, wherein the bracket is a structural element of the vehicle (2000) configured to bear a load from a vehicle component, wherein the bracket and the flexible skirt (1006) form a gapless seal. [10] Vehicle light (1000) according to claim 9, wherein the structural element of the vehicle (2000) is an outer sheet metal, a fender, a bumper (950) or another external component of the vehicle (2000). [11] Vehicle light (1000) according to claim 1, wherein the vehicle light (1000) is a headlight or a taillight. [12] Vehicle light (1000) according to claim 1, wherein the vertical axis (V) is aligned with a vertical edge (1017) of the lens (1002). [13] Vehicle light (1000) according to claim 1, wherein the horizontal axis (H) is aligned with a horizontal edge (1020) of the lens (1002). [14] Vehicle light (1000) comprising the following: a uniformly shaped lens (1002) made of optical silicone, having a vertical axis (V) extending along a vertical edge (1017) and a horizontal axis (H) extending along a horizontal edge (1020), wherein the uniformly shaped lens (1002) comprises the following: a front surface (1004) which is designed as a light exit; an integral reflector (1012) adjacent to the front surface (1004) to meet a prescribed light output; and a reinforcement structure arranged in the uniformly shaped lens (1002) to impart structural strength to the optical silicone, wherein the reinforcement structure has three alignment sections (1010), each of the three alignment sections (1010) having an alignment aperture (1038); a substrate (1008) forming a lamp chamber (1022) with the uniformly shaped lens (1002) in which a light source (1024) is housed, wherein the substrate (1008) is parallel to the three alignment sections (1010) and has three substrate openings (1028), each substrate opening (1028) being aligned to a corresponding alignment opening (1038); a two-axis adjustment mechanism (1030) comprising the following: three elements (1032, 1034, 1036), each element (1032, 1034, 1036) extending through the substrate opening (1028) which is aligned with the corresponding alignment opening (1038), the three elements (1032, 1034, 1036) having the following: a fixed element (1032) that is firmly connected to both the substrate (1008) and to one of the three alignment sections (1010) and is positioned on both the horizontal axis (H) and the vertical axis (V); a vertical adjustment device (1034) fixedly attached to a second of the three alignment sections (1010) and movable with respect to the substrate (1008), wherein the vertical adjustment device (1034) is positioned on the horizontal axis (H) and configured such that the one-piece molded lens (1002) can be adjusted with respect to the vertical axis (V); and a horizontal adjustment device (1036) fixedly attached to a third of the three alignment sections (1010) and movable with respect to the substrate (1008), wherein the horizontal adjustment device (1036) is positioned along the vertical axis (V) and configured such that the one-piece molded lens (1002) can be adjusted with respect to the horizontal axis (H); and a flexible skirt (1006) that frames the front surface (1004) of the one-piece molded lens (1002) and extends to the substrate (1008), wherein the flexible skirt (1006) is configured to maintain a gap-free seal during alignment with the two-axis adjustment mechanism (1030). [15] Vehicle light (1000) according to claim 14, wherein the flexible skirt (1006) is opaque and encloses the two-axis adjustment mechanism (1030) on a front side of the substrate (1008), wherein the two-axis adjustment mechanism (1030) is accessible from a rear side of the substrate (1008). [16] Vehicle light (1000) according to claim 14, wherein the two-axis adjustment mechanism (1030) is also accessible from a surface of the flexible skirt (1006). [17] Luminaire (1000) comprising the following: a lens (1002) having a front light exit surface (1004); at least three alignment sections (1010) extending from the lens (1002); a substrate (1008) arranged opposite the front light emission surface (1004) and positioned parallel to the at least three alignment sections (1010), with a flexible material between the substrate (1008) and the three alignment sections (1010), wherein the substrate (1008) has three openings aligned with the three alignment sections (1010); a two-axis adjustment mechanism (1030) comprising the following: three elements (1032, 1034, 1036), each element extending through a respective opening in the substrate (1008) and attached to a correspondingly oriented alignment section (1010), wherein the three elements (1032, 1034, 1036) have the following: a fixed element (1032) which is firmly connected to both the substrate (1008) and one of the three alignment sections (1010) and is positioned on both a horizontal axis (H) and a vertical axis (V) of the lens (1002); a vertical adjustment device (1034) which is fixedly attached to a second of the three alignment sections (1010) and movable with respect to the substrate (1008), wherein the vertical adjustment device (1034) is positioned on a horizontal axis (H) and configured such that a lens (1002) can be adjusted with respect to the vertical axis (V); and a horizontal adjustment device (1036) which is fixedly attached to a third of the three alignment sections (1010) and movable with respect to the substrate (1008), wherein the horizontal adjustment device (1036) is positioned along the vertical axis (V) and configured such that the lens (1002) can be adjusted with respect to the horizontal axis (H); and a flexible skirt (1006) which frames the front light exit surface (1004) of the lens (1002) without gaps, the flexible skirt (1006) extending towards the substrate (1008). [18] Luminaire (1000) according to claim 17, wherein: the lens (1002) is made of silicone; the three alignment sections (1010) extend from a reinforcement element molded in the silicone on opposite sides; and the flexible material is silicone in which the three alignment sections (1010) are embedded. [19] Luminaire (1000) according to claim 17, wherein the horizontal axis (H) is a horizontal edge of the lens (1002) and the vertical axis (V) is a vertical edge of the lens (1002). [20] Luminaire (1000) according to claim 17, wherein the vertical adjustment device (1034) is screwed to the substrate (1008) and the horizontal adjustment device (1036) is screwed to the substrate (1008).

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