Light module with a device for adjusting the alignment of a light beam with a light-dark boundary

Description

technical field

[0001] The present invention relates to the field of lighting, particularly automotive lighting. The invention specifically relates to a light module comprising an optical element configured to generate a beam of light with a cutoff line, that is, extending from one side of a cutoff line, as well as a device for adjusting the orientation of the cutoff line of the light beam. Without limiting the scope of this invention, the light module can be mounted in a lighting or signaling component, and / or in a motor vehicle headlight. State of the art

[0002] In the field of automotive lighting, light modules mounted in a vehicle's headlight are commonly known for projecting regulated beams of light known as "cut-off" beams, meaning beams extending beyond a cut-off line. This cut-off line, corresponding to the upper limit of the light beam, prevents the beam from extending too far upwards and obstructing the vision of people in front of the vehicle. This type of light module typically consists of a housing defining a compartment within which are arranged: at least one light source, an optical element positioned opposite this light source and configured to generate the "cut-off" light beam, and a device for adjusting the orientation of the cut-off line of the light beam in at least one direction (typically the vertical direction).Such a "cut-off" light beam is, for example, a fog light beam, although this is not a limiting case within the scope of the present invention. The light source(s) is or are typically a light-emitting diode (LED). The optical element is, for example, an optical reflector or a lens. When the optical element is a reflector, the light source(s) project light onto the reflector, and the light is then reflected through a cover plate to be projected into the vehicle's external environment, particularly onto the road.

[0003] The beam cutoff line orientation adjustment mechanism, which is linked to a part of the optical element, allows the height of the light beam emitted by the module to be varied so that it is neither too high nor too low. Activating the adjustment mechanism transmits a movement (typically a rotational movement) to the optical element, resulting in an adjustment of the light beam height.

[0004] A luminous module is known, comprising a housing defining a compartment within which are arranged: a light source, an optical reflector mounted to rotate relative to the light source and positioned opposite it, and a device for adjusting the orientation of the light beam generated by the optical reflector. The beam orientation adjustment device includes, for example, a rod with longitudinal gear splines. These longitudinal gear splines engage with curved rack and pinion systems located at the rear of the reflector, rotating the reflector around an axis of rotation when the beam orientation adjustment device is actuated.To enable this actuation, the rod is attached to a geared mechanism, which is itself connected to a receiving head for an adjustment tool external to the module. The receiving head protrudes from the housing through an opening in the latter. An operator can thus insert the adjustment tool into the receiving head of the device, which passes through the front or rear of the vehicle, thereby rotating the rod and consequently the reflector around the axis of rotation, and thus changing the direction of the light beam.

[0005] However, a drawback of the adjustment mechanism used in such a light module is that the adjustment of the light beam's orientation it allows is relatively imprecise. Furthermore, if mechanical vibrations are applied to the light module, the light beam is likely to move, thereby disrupting its orientation and potentially generating beam shaking and oscillation.

[0006] Other known light modules include a rotating optical element (such as a lens or reflector) and a beam orientation adjustment device consisting of a worm gear system. The worm gear typically engages with a threaded hole on the optical element or on a mounting plate for the optical element, allowing the beam orientation to be adjusted along a specific direction. However, a drawback of this type of light module is the need for a limit stop for the worm gear. The presence of such a stop necessitates the use of a disengagement mechanism to prevent damage to the product from contact with the stop. This increases both the production cost and the size of the light module. The disclosure of document DE 10 2012 024050 is also relevant for understanding the invention. Description of the invention

[0007] The present invention improves the situation.

[0008] One objective of the invention is to provide a light module according to claim 1.

[0009] The light beam generated by the optical element is a "cut-off" light beam. Such a "cut-off" light beam is, for example, a fog light beam, although this is not a limitation within the scope of the present invention. Adjusting the orientation of the cut-off line of the light beam along at least one adjustment direction preferably corresponds to positioning the cut-off line in the vertical direction. The optical element configured to generate the light beam is, for example, a reflector or a lens, although this is not a limitation within the scope of the present invention. When the optical element is a lens, the light module is more compact. When the optical element is a reflector, the optical and luminous performance of the light module is improved.Within the framework of the present invention, the device for adjusting the orientation of the cut line of the light beam is a device for adjusting the tilt of the optical element around the axis of rotation.

[0010] Thanks to this configuration of the beam adjustment device, which incorporates a cam and gear system with an eccentric, the beam orientation is adjusted more precisely and stably, resulting in a more compact and economical structure for the light module. This eccentric also imparts a pendulum-like motion to the optical element during adjustment of its rotation and the beam cutoff line orientation. This eliminates the need for stops and a disengagement mechanism, thereby reducing production costs and the overall size of the light module.

[0011] According to the invention, the cam and gear system further comprises a worm screw and a toothed wheel, the worm screw being provided with a receiving head for a tool or adjusting element external to the module, the toothed wheel being fixed to the camshaft and meshing with the worm screw.

[0012] According to a preferred embodiment of the invention, the worm gear and the toothed wheel define a reduction ratio, the worm gear and the toothed wheel being configured such that the reduction ratio is at least two, preferably two, the toothed wheel forming a reduction pinion. This improves the stability of the beam cutoff orientation adjustment. Such a reduction ratio effectively fixes the position of the camshaft (when the tool or adjustment device external to the module is not used), and thus essentially locks the tilt of the optical element in its adjustment position. This consequently prevents any misalignment of the beam cutoff orientation during the use of the light module.

[0013] According to one embodiment of the invention, the number of teeth of the gear is equal to twenty-eight. When the reduction ratio defined by the worm gear and by the gear is equal to two, this means that an operator equipped with the tool or adjusting element must make fourteen turns of the tool or adjusting element to perform a complete cycle from the minimum angular displacement to the maximum angular displacement of the optical element.

[0014] According to one embodiment of the invention, the camshaft is fixed by fitting into a receiving housing provided within the toothed wheel.

[0015] According to a preferred embodiment of the invention, an external face of the optical element is provided with a fork-shaped member, said fork-shaped member forming said portion of the optical element configured to cooperate with the eccentric when the camshaft is rotated, for rotating the optical element around the axis of rotation. Such a fork-shaped member thus provides an efficient, simple, compact, and inexpensive means of adjusting the inclination of the optical element around the axis of rotation, by cooperating with the rotation of the eccentric (obtained via the rotation of the camshaft by the external adjusting tool or member).

[0016] According to one embodiment of the invention, the eccentric is mounted to rest on a predefined inner edge of the fork-shaped organ, and is held between the two arms of the fork.

[0017] According to one embodiment of the invention, the optical element is made of a plastic material, preferably polycarbonate (also called PC). Preferably, when the optical element is a reflector made of a polycarbonate-type plastic material, the reflector has an aluminized coating (capable of reflecting light) on its inner surface. Preferably, the coating is applied to the reflector via a vacuum coating process.

[0018] According to a preferred embodiment of the invention, the shape of the eccentric is such that the angular deflection obtained for the optical element in the adjustment direction is between -4° and +4°. This makes it possible to reduce the number of revolutions of the tool or external adjusting member to the module required to sweep the entire angular deflection range of the optical element.

[0019] According to one embodiment of the invention, the eccentric has a substantially oval or ovoid shape. The shape of the eccentric is specifically optimized according to the available space within the housing.

[0020] Another object of the invention relates to a vehicle lighting and / or signaling element, in particular for a motor vehicle, comprising a light module according to the invention.

[0021] Here, "vehicle" means any type of vehicle such as a motor vehicle, a moped, a motorcycle, a warehouse storage robot, or any other machine capable of carrying at least one passenger or intended for the transport of people or objects.

[0022] According to one embodiment of the invention, the lighting and / or signaling element further comprises a heat sink fixed on top of the housing of the light module.

[0023] According to one embodiment of the invention, the lighting and / or signaling element is a vehicle fog light.

[0024] According to a preferred embodiment of the invention, the optical element comprises at least one pin projecting laterally from an upper face of the reflector, an upper face of the housing being provided with at least one pin receiving support, and an underside of the heat sink being provided with at least one pin locking member, the pin extending through a top opening in the housing and being pivotally mounted on the receiving support and in the locking member. This cooperation between the housing of the light module on the one hand and the heat sink on the other (respectively via the receiving support and the pin locking member), to ensure pivotal mounting and retention of the optical element, makes it possible to reduce the dimension chain as well as to ensure precision in the focusing obtained for the light beam, which advantageously reduces the angular deflection range required for the optical element.

[0025] Another object of the invention relates to a vehicle projector comprising a light module or a lighting and / or signaling element according to the invention. Brief description of the drawings

[0026] Other features and advantages of the invention will become apparent upon examination of the detailed description below, and the accompanying drawings in which: [ Fig 1 ] is a perspective view of a lighting and / or signaling element comprising a light module according to an embodiment of the invention; [ Fig 2 ] is an exploded perspective view of the lighting and / or signaling element of the figure 1 ; Fig 3 ] is a perspective view of the light module of the figure 1, in which certain components and parts have been omitted, the light module comprising an optical reflector, several light sources, and a device for adjusting the orientation of a cutoff line for the light beam; [ Fig 4 ] is a perspective view of the optical reflector, light sources, and adjustment device of the figure 3 ; Fig 5 ] is a first perspective view of the optical reflector and the adjustment device of the figure 3 , in which certain components and parts have been omitted; [ Fig 6 ] is a second perspective view of the optical reflector and the adjustment device of the figure 3 , in which certain components and parts have been omitted; [ Fig 7 ] is a perspective view of the adjustment device of the figure 3 ; And [ Fig 8 ] is an enlarged perspective view showing a detail of the adjustment device's implementation figure 7 .

[0027] In this document, unless otherwise specified, the terms "horizontal," "vertical," or "transverse," "lower," "upper," "above," "below," "top," "bottom," and "side" are defined with respect to the orientation of the light module 2 according to the invention, intended to be mounted in a vehicle lighting and / or signaling element 1. In particular, in this application, the term "vertical" designates an orientation perpendicular to the horizon, while the term "horizontal" designates an orientation parallel to the horizon.

[0028] Furthermore, anything designated as "rear" or "front" is designated relative to the face of the lighting and / or signaling element 1 closest to the exterior of the vehicle. Thus, anything designated as "rear" is located on the side furthest from the exterior of the vehicle along its principal direction of travel, while anything designated as "front" is located on the side closest to the exterior of the vehicle along its principal direction of travel. However, with regard to the vehicle's lights, these are designated as "front" or "rear" according to the rear-to-front orientation of the vehicle, i.e., its conventional direction of travel. Detailed description

[0029] THE figures 1 to 3represent a vehicle lighting and / or signaling element 1 comprising the light module 2 according to the invention. The light module 2 is integrated into the front or rear of the vehicle and includes a housing 4, preferably hermetically sealed. The lighting and / or signaling element 1 further includes a heat sink 6 fixed to the top of the housing 4, as well as an auxiliary protective housing 8 fixed to one side of the housing 4 (for example, by means of a screw 9) and defining a recess. The heat sink 6 dissipates the heat emitted by light sources arranged within the housing 4. The heat sink 6 is, for example, a radiator, typically an aluminum radiator. The lighting and / or signaling element 1 is, for example, a front or rear fog light for a vehicle (without this being a limitation within the scope of the present invention) and can typically be part of a vehicle headlight.

[0030] The housing 4 is conventionally closed by a closing glass 10. The housing 4 defines a compartment 12 within which are arranged several light sources (not shown in the figures for clarity), an optical element 16 configured to generate a light beam extending from one side of a cutoff line (such a cutoff line not being shown in the figures for clarity), and a device 18 for adjusting the orientation of the cutoff line of the light beam along at least one adjustment direction. According to the particular embodiment illustrated in the figures 1 to 8 The optical element 16 is a reflector, and the adjustment device 18 is configured to allow adjustment of the beam cutoff line orientation in a single direction. The adjustment direction is preferably vertical. Preferably, as shown in the figures 1 to 4, the light module 2 also includes, arranged within housing 12, a mask 17 and a sealing gasket 19.

[0031] In the specific implementation example illustrated on the figures 1 to 4 The light sources, which are light-emitting diodes (LEDs), are mounted on a printed circuit board (PCB) 20, itself positioned below, near, and opposite the heat sink 6. The PCB 20 thus closes the top of the housing 4, with the light sources extending into the recess 12 defined by the housing 4. The PCB 20 is secured beneath the heat sink 6 by several screws 21, and the heat sink 6 is also secured to the housing 4 by several screws 22.

[0032] The reflector 16 is positioned opposite the light sources. More precisely, in the example of the implementation of the figures 1 to 4The reflector 16 is positioned below the light sources and has a concave inner face 23 facing these light sources (thus giving the reflector 16 an overall parabolic shape). In this way, the light sources illuminate the concave inner face 23 of the reflector 16, causing optical reflection of the light rays on the reflector 16 and generating the light beam that extends from one side of the cutoff line. The light beam is then directed towards the optic 10. The reflector 16 typically has grooves 24A and 24B, distributed, for example, between a first set of vertical grooves 24A and a second set of horizontal grooves 24B. The vertical grooves 24A of the first set of grooves, also called "cavity grooves," ensure even distribution of the light across the entire field of the light module 2.The horizontal grooves 24B of the second set of grooves prevent unwanted light reflections and effectively diffuse the light to achieve the required beam shape (with a clearly defined cutoff line), thus preventing glare. The reflector 16 is mounted to rotate around an axis A-A'. This is achieved in the example of the... figures 2 to 6 The reflector 16 is equipped with two upper cylindrical pins 25 which project laterally and horizontally on either side of the reflector 16, from an upper face of the latter. As illustrated in the figure 2The upper face of the housing 4 is provided with two supports 27 for receiving the pins 25 (which may, for example, be indentations or notches), on which the pins 25 rest and which allow indexing of the reflector 16 in the vertical direction. The reflector 16 is pivotally mounted on the supports 27 via its pins 25. Furthermore, the heat sink 6 is advantageously provided on its inner face with two locking elements 29 for the pins 25 in the horizontal direction, such elements 29 being, for example, forked. The reflector 16 is also pivotally mounted in the locking elements 29 via its pins 25. The two locking elements 29 ensure indexing and isostatic positioning of the reflector 16 in the horizontal direction. To enable this cooperation between the pins 25 of the reflector 16 and the blocking elements 29 of the heat sink 6, two cutouts 31 (visible on the figure 3Openings are provided in the printed circuit board 20, which allow the pins 25 to pass through the board 20 (the pins also extending through a top opening 56 in the housing 4). In an alternative not shown, the reflector 16 can be mounted directly within the housing 4, for example via a pivot support or rotation cradle for the reflector 16 provided in the housing 4. Such a pivot support or rotation cradle typically takes the form of pins or clips directly overmolded into the housing 4, onto which the reflector 16 is positioned to be held and thus allow the reflector to be rotated around the axis of rotation.

[0033] The reflector 16 is, for example, made of a plastic material, preferably polycarbonate. The reflector 16 typically has an aluminized coating (capable of reflecting light) on its concave inner face 23. Preferably, the coating is applied to the reflector 16 via a vacuum coating process.

[0034] Preferably, the light sources are aligned on the printed circuit board 20 along an axis, this axis coinciding with the rotation axis AA' of the reflector 16.

[0035] Preferably, an external face 26 (typically convex) of the reflector 16 is provided with a fork-shaped element 28. The fork-shaped element 28 is thus located at the rear of the reflector 16, on the side opposite the light sources to the wall of the reflector 16. Such a fork-shaped element 28, whose arms are preferably oriented downwards, is particularly visible at figures 5 and 6Preferably, the arms of the fork-shaped element 28 together define a general plane of extension. The fork-shaped element 28 forms an appendage projecting from the rear of the reflector 16 and extending substantially transversely to the wall of the reflector 16. The reflector 16 and the fork-shaped element 28 preferably form a single piece of material.

[0036] The adjustment device 18 is a manual adjustment device linked to the reflector 16. The adjustment device 18 is configured to cooperate with an external tool or adjusting element outside the module 2 (such a tool or adjusting element is not shown in the figures for clarity), so as to rotate the reflector 16 around its axis of rotation and thus change the orientation of the cutoff line of the light beam. The tool or adjusting element configured to cooperate with the adjustment device 18 is, for example, a screwdriver.

[0037] The adjustment device 18 includes a cam and gear system 36. The cam and gear system 36 includes a camshaft 38 and an eccentric 40 fixed to the camshaft 38. Preferably, the cam and gear system 36 further includes a worm gear 42, a toothed wheel 44 and a sealing O-ring 46.

[0038] As illustrated on the figures 6 to 8 The camshaft 38 is, for example, fixed by fitting into a receiving housing 48 formed in the toothed wheel 44. The receiving housing 48 is, for example, defined by the inside of a central sleeve 49 attached to the toothed wheel 44. The receiving housing 48 forms, for example, a hexagonal cavity complementary to the shape of the camshaft 38 and allowing the latter to be fixed in the toothed wheel 44, without this being limiting.

[0039] The eccentric 40 is configured to cooperate with a portion of the reflector 16 when the camshaft 38 is driven in rotation, to drive the reflector 16 in rotation around the axis of rotation A-A'. More specifically, in the preferred embodiment shown in the figures 4 to 8The eccentric 40 is configured to cooperate with the fork-shaped member 28 when the camshaft 38 is rotated, thereby rotating the reflector 16 around the axis of rotation A-A'. The camshaft 38 then extends orthogonally to the general plane of extension defined by the arms of the fork-shaped member 28. The eccentric 40 is mounted against an inner edge 51 of the fork-shaped member 28 and is held between the two arms of the fork. In this way, the rotation of the eccentric (which has an asymmetrical shape of revolution) causes the fork-shaped member 28 to move rearward or forward, which in turn causes the reflector 16 to rotate around the axis of rotation A-A'. The shape of the eccentric 40 is advantageously chosen to optimize the available space within the housing 4, as well as the angular displacement of the reflector 16 within the light module 2.In the example of preferred realization shown on the . figures 2 to 8 The eccentric 40 has a roughly oval or ovoid shape. The shape of the eccentric 40 is such that the angular deflection obtained for the reflector 16 in the adjustment direction (here the vertical direction) is preferably between -4° and +4°.

[0040] The worm gear 42 is equipped with a receiving head 50 for the tool or adjusting element external to the light module 2. The receiving head 50 extends through an opening (not shown) provided for this purpose in the front or rear face of the vehicle, so as to be accessible to a user positioned in front of this face and equipped with the tool or adjusting element. The worm gear 42 extends in a direction substantially orthogonal to the principal plane in which the toothed wheel 44 extends, and meshes with the toothed wheel 44.

[0041] The gear 44 forms a reduction gear and is fixed at its center to the camshaft 38. The worm gear 42 and the gear 44 define a reduction ratio. The worm gear 42 and the gear 44 are configured such that the reduction ratio is at least two, preferably two. In the particular embodiment of the figures 2 to 8 , the toothed wheel 44 has twenty-eight teeth, without this being a limiting factor.

[0042] As illustrated on the figures 2 , 3 , 4 And 5 The worm gear 42 and the toothed wheel 44 are arranged within the housing defined by the auxiliary protective housing 8, outside the housing 4. Only the central sleeve 49 of the toothed wheel 44 extends partly into the housing 12 defined by the housing 4 and passes through an opening (not shown) provided for this purpose in the housing 4.

[0043] The sealing O-ring 46 is arranged around the central sleeve 49 of the gear 44, inside the housing 12 in contact with an internal side wall of the housing 4. The O-ring 46 ensures the sealing of the interface formed between the housing 4 and the auxiliary protective housing 8. The O-ring 46 is, for example, made of silicone.

[0044] Mask 17 forms an aesthetic outline or screen for the light module 2, visible from outside the vehicle. Its shape allows mask 17 to only leave the reflector 16 visible from the outside. As illustrated on the figure 2The mask 17 is mounted in a lateral opening 54 of the housing 4 and forms a support for the optic 10, which is then attached to the mask 17 by snapping it into place through the lateral opening 54. The sealing gasket 19 is configured to fit around the perimeter of a top opening 56 in the housing 4 and is positioned on top of the housing 4, between the heat sink 6 and the housing 4. The sealing gasket 19 is, for example, made of silicone. The heat sink 6 is thus fixed to the housing 4 above the top opening 56, opposite it, and compresses the sealing gasket 19. The printed circuit board 20 extends into the top opening 56 of the housing 4, below the heat sink 6.

[0045] During operation, a user equipped with the adjustment tool or device (typically a screwdriver) inserts this tool or device into the receiving head 50 of the worm gear 42. By rotating the worm gear 42, the latter drives the toothed wheel 44, which in turn drives the camshaft 38 and the eccentric 40. The rotation of the eccentric 40, which cooperates with the fork-shaped element 28, causes this element 28 to move backward or forward, which in turn causes the reflector 16 to rotate around the axis of rotation A-A'. This allows the orientation of the cutoff line of the light beam generated by the reflector 16 to be adjusted according to the direction of adjustment (here, the vertical direction).

[0046] The present invention is not limited to the embodiments described above by way of example and extends to other variants.

Claims

1. Light module (2) integrated in the front or rear face of a vehicle, the light module (2) comprising a housing (4) defining a compartment (12) inside which are arranged: at least one light source, an optical element (16) arranged facing said at least one light source and configured so as to generate a light beam extending from one side of a cut-off line, and a device (18) for adjusting the orientation of the cut-off line of the light beam according to at least one adjustment direction, the optical element (16) being mounted movably around a rotation axis (A-A'), said adjustment device (18) being a manual adjustment device and being linked to said optical element (16) and being configured to cooperate with a tool or adjustment member external to the module, so as to rotate the optical element (16) around the rotation axis (A-A') relative to the housing and to modify the orientation of the cut-off line of the light beam; characterized in that the at least one light source is mounted fixed relative to said housing, in that the optical element (16) is a reflector (16) and in that the device (18) for adjusting the light beam comprises a cam and gear system (36) provided with a cam shaft (38) and an eccentric (40), said eccentric (40) being secured to the cam shaft (38) and being configured to cooperate with a part (28) of the optical element (16) when the cam shaft (38) is rotated, to rotate the optical element (16) around the rotation axis (A-A'), the cam and gear system (36) further comprises a worm screw (42) and a toothed wheel (44), the worm screw (42) being provided with a head (50) for receiving said tool or adjustment member external to the module, the toothed wheel (44) being secured to the cam shaft (38) and meshing with the worm screw (42).

2. Light module (2) according to claim 1, wherein the worm screw (42) and the toothed wheel (44) define a reduction ratio, the worm screw (42) and the toothed wheel (44) being configured such that the reduction ratio is equal to at least two, preferably equal to two, the toothed wheel (42) forming a reduction pinion.

3. Light module (2) according to claim 2, wherein the number of teeth of the toothed wheel (44) is equal to twenty-eight.

4. Light module (2) according to any one of claims 1 to 3, wherein the cam shaft (38) is fixed by fitting into a receiving housing (48) provided within the toothed wheel (44).

5. Light module (2) according to any one of the preceding claims, wherein an external face (26) of the optical element (16) is provided with a fork-shaped member (28), said fork-shaped member (28) forming said part of the optical element (16) configured to cooperate with the eccentric (40) when the cam shaft (38) is rotated, for rotating the optical element (16) around the rotation axis (A-A').

6. Light module (2) according to claim 5, wherein the eccentric (40) is mounted in contact with a predefined inner edge (51) of the fork-shaped member (28), and is maintained between the two branches of the fork.

7. Light module (2) according to any one of the preceding claims, wherein the optical element (16) is made of a plastic material, preferably polycarbonate.

8. Light module (2) according to any one of the preceding claims, wherein the shape of the eccentric (40) is such that the angular travel obtained for the optical element (16) in the adjustment direction is between -4° and +4°.

9. Light module (2) according to claim 8, wherein the eccentric (40) has a substantially oval or ovoid shape.

10. Vehicle lighting and / or signaling element (1) comprising a light module (2) according to any one of the preceding claims.

11. Vehicle lighting and / or signaling element (1) according to the preceding claim, wherein the lighting and / or signaling element (1) further comprises a heat sink (6) fixed on top of the housing (4) of the light module (2).

12. Vehicle lighting and / or signaling element (1) according to the preceding claim, wherein the optical element (16) comprises at least one pin (25) that protrudes laterally from an upper face of the reflector (16), an upper face of the housing (4) being provided with at least one support (27) for receiving the pin (25), and a lower face of the heat sink (6) being provided with at least one blocking member (29) for the pin (25), the pin (25) extending through an upper opening (56) of the housing (4) and being pivotally mounted on the receiving support (27) and in the blocking member (29).

13. Vehicle headlight comprising a light module (2) according to any one of claims 1 to 9 or a lighting and / or signaling element (1) according to any one of claims 10 to 12.