Optical module with common part reference for motor vehicle lighting and / or signalling

Abstract

The invention relates to an optical module (1) for a vehicle lighting and / or signalling device, comprising at least one light source (2, 7) to (9) able to generate a light beam, a cooling device (3) able to dissipate heat and a device (4) for focusing the light beam, characterized in that the focusing device (4) is carried directly by the cooling device (3).

Description

[0001] The technical field of the present invention relates to optical modules designed to produce a light beam for illuminating a road traveled by a vehicle equipped with this optical module. Such an optical module finds particular application when installed within a lighting and / or signaling device for a motor vehicle.

[0002] It is known to achieve a lighting function on a motor vehicle by focusing beams of light emitted from a light source. The optical components used to focus these beams of light are generally installed between the light source, for example a xenon bulb, and the lens of a headlight that houses this assembly.

[0003] Such an optical piece is an isotropic and transparent element, and of which at least one face is not flat, so as to converge or diverge the light.

[0004] In the automotive lighting sector, it is also common to use a light-emitting diode (LED) light source. This type of source is accompanied by a switch that turns the source on or off, and both components generate heat that a cooling system is responsible for dissipating into the surrounding environment.

[0005] Mounting a prior art optical component with an assembly consisting of a light-emitting diode (LED) and its cooling device is achieved by interposing a component that maintains a certain distance between the optical component and the assembly. This component is generally a plastic support that is fixed on one side to the periphery of the optical component and on the other side to the LED and its cooling device assembly.

[0006] The presence of this support has many drawbacks. First, this support is a component that must be designed, manufactured, and installed. This component therefore represents a cost that increases the overall cost of the lighting function.

[0007] Another drawback lies in the fact that this support is a separate, intermediate part between the assembly mentioned above and the optical component. Since the latter must be installed with a precise orientation relative to the assembly, it is necessary to manage, on the one hand, the dimensional chain connecting these components with great precision, and on the other hand, to guarantee a minimum manufacturing tolerance for this intermediate support.

[0008] The aim of the present invention is therefore to resolve the disadvantages described above mainly by directly referencing the optical part to the cooling device.

[0009] US patent documents 2010 / 073950 A1 and KR 2009 0052038 A disclose an optical component held either by the cooling device or by an assembly including a reflector. However, the solution proposed in these documents remains improvable.

[0010] The invention therefore relates to an optical module for a lighting and / or signaling device of a vehicle according to claim 1.

[0011] The function of the focusing device is to concentrate the light rays emitted by the source and direct them towards a specific area of ​​the road to be illuminated. Such a focusing device is, for example, a lens, or a series of lenses.

[0012] According to a first feature of the invention, the cooling device comprises at least a first portion intended to capture calories and at least a second portion originating from said first portion, that is to say, which emerges from the latter, and on which the focusing device rests.

[0013] According to a second feature of the invention, the second portion comprises a cavity in which is housed an outgrowth of the focusing device, said outgrowth being delimited by at least two walls of complementary shape to at least two faces delimiting the cavity.

[0014] According to another feature of the invention, the module includes at least one collector, or collector element comprising a plurality of collectors, capable of reflecting the light beam emitted by the light source at least towards the focusing device.

[0015] According to another feature of the invention, a fastening means is provided to secure the focusing device to the cooling device.

[0016] According to another feature of the invention, the fastening means for securing the focusing device to the cooling device is made of the same material as the collector.

[0017] Advantageously, the collector is secured to the cooling device by at least one securing element, said securing element being arranged to press the protrusion into the cavity.

[0018] Even more advantageously, the fixing means is formed by an arch of which at least one side is in contact with an edge of the focusing device.

[0019] According to a characteristic of the optical module, the fastening means includes at least one deformable element.

[0020] The optical module according to the invention comprises at least one printed circuit board in direct contact with the cooling device, said printed circuit board receiving said light source.

[0021] The module still includes at least one folding machine in direct contact with the cooling device.

[0022] The invention also covers a lighting and / or signaling device for a motor vehicle comprising at least one optical module according to any one of the characteristics presented above.

[0023] Such a device is arranged to participate in the production of a code function of a motor vehicle.

[0024] A primary advantage of the invention lies in the elimination of a component in an optical module intended for use on a motor vehicle. This can reduce the cost of the lighting function implemented by the optical module according to the invention.

[0025] Another advantage lies in the improved reliability of the assembly of such a module. Indeed, the rib chain between the light source and the focusing device is reduced, which increases the level of precision and reliability of the module according to the invention.

[0026] Other features, details and advantages of the invention will become clearer upon reading the description given below by way of example in conjunction with drawings in which: there figure 1 is a perspective view of an optical module not covered by claim 1, the figure 2 is a detailed side view showing the relationship between the cooling device and the focusing device, the figure 3 is a partial, top-down view showing a central point of connection between the cooling device and the focusing device, the figure 4 is a detailed and perspective view of the fastening means not covered by claim 1, the figure 5 is a perspective view of the fastening method, the figure 6 is an exploded view of the optical module shown in the figure 1 , there figure 7 is a perspective view of a component according to a first embodiment of the optical module according to the invention, the figure 8 is a perspective view of the first variant of the optical module according to the invention, the figure 9 is a perspective view of a component of the optical module according to a second embodiment, the figure 10 is a perspective view of the second variant of the optical module.

[0027] There figure 1 This illustrates an optical module 1 not covered by claim 1. Such an optical module is intended to be integrated inside a headlight or front headlight of a motor vehicle. The function of this optical module 1 is to generate at least one light beam and to project this beam onto a road traveled by the vehicle. Such an optical module contributes to the creation of a low beam or a high beam, the description below being limited to the example of a low beam.

[0028] This optical module 1 includes at least one light source 2 which forms the element generating the light rays of the light beam. Since this light source 2 emits heat, the optical module 1 also includes a cooling device 3 designed to capture at least the heat generated by the light source 2 and dissipate it into the air surrounding the optical module 1. This cooling device 3 is notably formed by a radiator or heat sink made of an aluminum alloy.

[0029] The optical module 1 also includes a focusing device 4 whose function is to concentrate the light rays emitted by the source and direct them towards the area of ​​the road to be illuminated. Such a focusing device 4 is, for example, a lens 5, or a combination of lenses 5 and 6.

[0030] According to the invention, the focusing device 4 is carried directly by the cooling device 3. It is understood from this that the focusing device is in physical contact with the cooling device, without any intermediate part or element other than the fastening means which will be detailed below.

[0031] According to the embodiment shown in this figure, the optical module 1 can be improved by including a plurality of light sources 2, 7, 8, and 9, in particular four light sources. This optical module 1 is then capable of projecting a first light beam and a second light beam. In one embodiment, the first light beam, when projected onto a screen perpendicular to an optical axis of the module, presents a planar cutoff to fulfill the coded function of a lighting device. The second light beam can then form a road-type beam. Alternatively, the second light beam can form, when projected onto a screen perpendicular to the optical axis, a cutoff edge comprising two branches forming a non-zero angle with each other, which corresponds to a coded beam type.

[0032] According to one embodiment, the first light beam is generated by a first pair of light sources 2 and 7, while the second light beam is generated by a second pair of light sources referenced 8 and 9.

[0033] The cooling device 3 includes a first portion 10 designed to capture the heat generated, among other things, by the light source(s) 2, 7 to 9. This first portion 10 receives a printed circuit board 11 which rests on an upper face of the first portion. This printed circuit board 11 carries at least one of the light sources, and advantageously all four light sources.

[0034] The cooling device 3 includes at least a second portion 12 which opens from the first portion 10 and which is made of the same material as this first portion 10. In the example of the figure 1 , the cooling device 3 includes a second portion 12 which takes for example the form of a first arm 12a and a second arm 12b each made at one end of the first portion 10.

[0035] The second portion 12 is an outgrowth on which the focusing device 4 is placed.

[0036] In the example of the figure 1 , it should be noted that the light source(s) 2 and 7 to 9 are light-emitting diodes, for example of single-chip type or multi-chip type.

[0037] The printed circuit board 11 also carries electronic components, some of which are dedicated to switching one or more light sources 2, 7 to 9 on or off. These components also generate heat, and the contact between the printed circuit board 11 and the first portion 10 of the cooling device 3 allows this heat to be dissipated into the air surrounding the optical module 1.

[0038] The optical module 1 according to the invention further comprises at least one bender 13a whose function is to block the portion of the light beam extending above the horizontal axis. This bender 13a is used when the optical module according to the invention participates in the production of the vehicle's code function. Such blocking, in other words, a cutting of the beam, is performed by a cutting edge 14 forming part of the bender 13a.

[0039] In the example of the figure 1 , the optical module includes two folding machines 13a and 13b, the first of which, referenced 13a, is dedicated to a first pair of light sources 2 and 7, while a second folding machine, referenced 13b, is dedicated to the second pair of light sources 8 and 9.

[0040] The optical module 1 according to the invention may also include at least one collector 14a capable of reflecting the light beam emitted by the light source 2 at least towards the focusing device 4. Such a collector 14a is a dome-shaped piece that covers the light source 2. This collector 14a has an inner face 15 which is reflective so as to reflect a maximum of light rays towards the focusing device 4.

[0041] In the example of the figure 1 The optical module comprises a multiplicity of collectors, in particular three collectors 14a, 14b and 14c assembled to form a collector element 42. A first collector 14a covers the first light source 2, a second collector 14b covers the second light source 7 and a third collector 14c covers the pair formed by the third and fourth light sources 8 and 9. To do this, the third collector 14c has a section with double radii of curvature.

[0042] The focusing device 4 is connected by physical contact to the second part 12 of the cooling device 3. The focusing device 4 is secured to the first arm 12a and to the second arm 12b by a fastening means 16 which will be discussed in detail in the following figures.

[0043] There figure 2 shows in detail how the focusing device 4 cooperates with the cooling device 3. We see the first arm 12a at the end of which is provided a cavity 17. The latter is delimited by a first face 18 and by a second face 19. This first face 18 extends in a plane which forms an acute angle with a plane which passes through the second face 19. Such an arrangement makes it possible to form the cavity 17 in the shape of a “V”.

[0044] The focusing device 4 comprises two ends along the horizontal axis. At least one of its ends, and advantageously both, includes a projection 20 extending from this end along the horizontal axis. This projection 20 has a shape, in particular a cross-section, that is complementary to the shape of the cavity 17. Thus, this projection 20 fits into the cavity 17, thereby providing initial mechanical support between these two parts.

[0045] The protrusion 20 is delimited by a first wall 21 and by a second wall 56. This first wall 20 extends in a plane which forms an acute angle with a plane which passes through the second wall 56. The plane in which the first wall 21 extends is also substantially parallel to the plane in which the first face 18 extends. The plane in which the second wall 56 extends is also substantially parallel to the plane in which the second face 19 extends.

[0046] The mechanical link between the cooling device 3 and the focusing device 4 is reinforced by the addition of a connection point 22 shown on the figure 3 As an example, this connection point 22 is formed between a first lens 5 and a second lens 6, which are part of the focusing device 4. The connection point 22 includes a housing 23 with a U-shaped cross-section. This housing 23 is formed by a stud 24 made from the same material as the cooling device 3. On the side of the focusing device 4, the latter includes a finger 25 made from the same material as the focusing device 4, particularly during its molding. The connection is made when the finger 25 enters the housing 23, for example, by being press-fitted into it.

[0047] This connection point 22 ensures longitudinal centering of the focusing device 4 with respect to the cooling device 3.

[0048] There figure 4 shows in perspective the detail of the mechanical link operated between the cooling device 3 and the focusing device 4. The protrusion 20 emerges from a slice 26 which borders the first lens 5 and fits into the cavity 17 made at the end and in the thickness of the first arm 12a.

[0049] The fastening means 16 performs three functions in combination. Its first function is to ensure that the protrusion 20 remains within the cavity 17. This prevents any movement and any possibility of the focusing device becoming decoupled from the cooling device. The second function is to absorb the dimensional tolerances of the cooling device or the focusing device. The third function is an intrinsic resilience that allows the fastening means 16 to accommodate, to a certain extent, expansion, particularly thermal expansion.

[0050] The protrusion 20 is delimited by an upper face. From this face emerges a lug 27 which cooperates with a hole 28 provided at one end of the fastening means 16. This hole 28 and this lug 27 form a locking means for the fastening means 16.

[0051] At the other end of the fastening means 16 there is a shoulder 36 which cooperates with the first arm 12a, a free end of the fastening means 16 coming into contact on one side and on a lower edge of the first arm 12a.

[0052] According to a practical embodiment, the fastening means 16 is a clip that engages both with the focusing device 4 and with the cooling device.

[0053] Finally, it should be noted that this fastening means 16 according to this first variant of the embodiment is removable independently of the other components, this fastening means being made by a separate part and distinct from the other components of the optical module 1.

[0054] There figure 5 Figure 16 shows the structure of this fastening means. It has a function of absorbing dimensional tolerances of the focusing device and / or the cooling device. It also has a function of absorbing the expansion of these components resulting from heat loss.

[0055] The fastening means 16 is thus formed by a tab, i.e., a metal strip. This fastening means comprises at least one deformable means 30 made in the form of three folds 31, 32 and 33. These three folds give the fastening means flexibility along its length.

[0056] The first end of the fastening means is finished with a flat 34 bent at a right angle and through which the hole 28 is provided. The second end includes a "V"-shaped fold 35 continued by the shoulder 36.

[0057] There figure 6 The illustration shows the various components of an exemplary embodiment of the optical module 1 not covered by claim 1. The cooling device 3 forms a common support to which these components are attached. As explained above, the focusing device 4 rests on the second portion 12 of the cooling device and is held directly to it by a fastening means 16, consisting here of two clips. The second portion 12 thus comprises at least the first arm 12a and the second arm 12b.

[0058] The first portion 10 of the cooling device 3 comprises a plurality of first centering guides 37 onto which the printed circuit board 11 is inserted. These centering guides ensure the positioning of the printed circuit board 11 relative to the cooling device 3 because the light sources 2, 7 to 9 are installed on the printed circuit board 11, advantageously on the same side thereof. The first centering guides 37 are molded with the cooling device 3. They cooperate with openings 38 formed through the printed circuit board 11.

[0059] We understand from the previous paragraph that the cooling device serves as a mechanical reference for the light sources, in particular via the printed circuit board, the latter being in direct contact with the cooling device.

[0060] The first portion 10 also includes a series of second centering devices 39 which ensure the positioning of the bending device 13a or 13b, the latter being assembled so as to form a single part referenced 40. This part, whose function is to generate the cutting of a coded beam, includes holes 41 into which the second centering devices 39 penetrate. It is also understood here that the cooling device forms a mechanical reference for the part 40 forming the bending device, the latter being directly in contact or resting on the cooling device.

[0061] The printed circuit board 11 and the bending part 40 are interposed between the cooling device 3 and the collector element 42, which combines at least two collectors 14a and 14b into one piece. In this embodiment, the collector element 42 comprises the three collectors 14a, 14b, and 14c detailed in the figure 1 . This collector element 42 is a molded plastic part whose internal faces 15 include an aluminized layer, which allows it to reflect the light rays emitted by the light sources.

[0062] The final attachment of the collector element 42 to the cooling device 3 is ensured by a fastening element 43. Advantageously, this fastening element 43 also ensures the final attachment of the printed circuit board 11 and / or the bending part 40. In this example, this fastening element consists of at least one screw 44 which engages in a corresponding threaded hole 45 provided in the cooling device 3.

[0063] There figure 7 represents at least one collector 14a and a fastening means 16 according to an example of an embodiment of the invention. As for the figure 6 , the plurality of collectors 14a, 14b and 14c is brought together in one piece made by a collector element 42 but it is quite clear that the description below covers a minimal combination comprising a single collector.

[0064] Unlike the example illustrated on the figures 1 à 6 Not covered by claim 1, the fastening means is not provided by a separate and distinct part. This fastening means is an integral part of the collector element 42. This fastening means 16 is thus formed by at least a first arm 46 and a second arm 47 made of the same material as the collector element 42. These two arms extend in the direction of the optical axis of the module and have a shape complementary to the first arm, respectively second arm, of the second portion constituting the cooling device.

[0065] We now refer to the figure 8 The fastening means 16 detailed here includes a deformable element 30, the functions assigned to this deformable means being identical to those mentioned in relation to the first variant. This deformable means 30 lies in the flexibility of the material constituting the first and second arms 46 and 47. Indeed, the plastic material used for manufacturing the collector element is chosen for its resilience, capable of absorbing tolerance deviations and expansions.

[0066] Alternatively or in addition, this flexibility can be achieved by the particular shape of the branches, especially their thickness.

[0067] This figure further shows that a free end of the first branch 46 and of the second branch 47 includes a hook 48 of which a beveled face 49 comes to enclose the protrusion 20 of the focusing device 4 in the cavity 17 of the cooling device 3.

[0068] The fastening means 16 is furthermore attached to the second portion 12 of the cooling device 3 by means of a fastening element 43. For this purpose, the first arm 46 and / or the second arm 47 include a hole through which the fastening element 43 passes, the latter engaging in a thread provided in the first arm 12a and / or the second arm 12b.

[0069] There figure 9 illustrates at least one collector 14a and a fastening means 16 according to a third embodiment of the invention. As with the preceding figures, the plurality of collectors 14a, 14b and 14c are assembled into a single piece formed by a collector element 42, but it is clear that the description below covers a minimal combination comprising a single collector.

[0070] As with the second variant of the invention, the fastening means is an integral part of the collector element 42. This fastening means 16 is here formed by an arch 50.

[0071] Such an arch 50 has a general "U" shape. A first side 51 forms the base of the "U" and this first side 51 is connected to the collector element 42 by at least a second side 52 and a third side 53 each located at one of the ends of the collector element 42, according to the extension direction of the collectors 14a, 14b and 14c.

[0072] The arch 50 may advantageously include an intermediate flank 54 which connects the first flank 51 to the rest of the collector element 42 at a point located between two collectors 14b and 14c.

[0073] As with the second variant, the collector element 42, the first flank 51, the second flank 52, the third flank 53, and possibly the intermediate flank 54, form a single piece, notably resulting from the same molding stage.

[0074] On the figure 10 , the first flank 51 is formed by a flat which follows two radii of curvature, each of the radii of curvature being substantially identical to the radius of curvature followed by the first lens 5 and by the second lens 6.

[0075] The focusing device 4 is attached to the cooling device 3 as follows. The collector element 42, equipped with the bracket 50, is installed on the printed circuit board 11 and on the bending element 40. The first side 51 is then pressed against or brought into contact with an edge 55 of the focusing device 4 so as to exert a force that presses the protrusion 20 into its cavity 17. The installation of the fastening device 43, in particular the screws 44, permanently secures the focusing device 4 to the cooling device 3.

[0076] The deformable element 30 of the fastening means 16 is implemented here by the determined flexibility of the first flank 52, the second flank 53, and possibly the intermediate flank 54, when the optical module 1 according to the invention is made up of it.

[0077] One or more optical modules 1 can be integrated into a lighting and / or signaling device mounted on a motor vehicle. In particular, it can contribute to the production of a low beam, i.e., with a flat cutoff or a cutoff inclined at a non-zero angle, for example between 8° and 15°.

Claims

1. Optical module (1) for a lighting and / or signaling device of a vehicle, comprising at least one light source (2, 7 to 9) capable of generating a light beam, a cooling device (3) capable of dissipating heat and a focusing device (4) for the light beam, the focusing device (4) being directly carried by the cooling device (3), wherein: - the cooling device (3) comprises at least a first portion (10) intended to capture heat and at least a second portion (12) extending from said first portion (10) and on which the focusing device (4) rests; - the second portion (12) comprises a cavity (17) in which a protrusion (20) of the focusing device (4) is housed, said protrusion (20) being delimited by at least two walls (21, 56) of complementary shape to at least two faces (18, 19) delimiting the cavity (17); - the module comprises: • at least one collector (14a, 14b, 14c, 42) capable of redirecting the light beam emitted by the light source (2, 7 to 9) at least toward the focusing device (4); • a fastening means (16) for securing the focusing device (4) to the cooling device (3), characterized in that said fastening means (16) is formed integrally with the collector (14a, 14b, 14c, 42).

2. Module according to claim 1, wherein the collector (14a, 14b, 14c, 42) is secured to the cooling device (3) by at least one securing element (43), said securing element (43) being arranged to press the protrusion (20) into the cavity (17).

3. Module according to any one of the preceding claims, comprising at least one printed circuit board (11) directly in contact with the cooling device (3), said printed circuit board (11) receiving said light source (2, 7 to 9).

4. Module according to any one of the preceding claims, comprising at least one folder (13a, 13b, 40) directly in contact with the cooling device (3).

5. Module according to any one of the preceding claims, wherein the focusing device is a lens, or a multiplicity of lenses.

6. Lighting and / or signaling device for a motor vehicle comprising at least one optical module (1) according to any one of the preceding claims.

7. Device according to claim 6, arranged to participate in the production of a dipped beam function of a motor vehicle.

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