Optical-module assembly for a motor-vehicle lighting and / or signalling device

Abstract

The invention relates to an optical module (12) for a motor-vehicle lighting and / or luminous-signalling device, said optical module (12) comprising a housing (102) obtained after assembling a carrier plate (120) receiving at least one light source (SEL) and a shell (220) defining at least one reflector (202) that faces the light source (SEL); the housing (102) defines a hollow body comprising an aperture in the front face of the housing (102), which aperture is closed by a projection lens (320) that is capable of allowing light emitted by the light source (SEL) to diffuse to the exterior of the module (12) and that interacts with the reflector to form a determined type of light beam, said lens (320) being shaped so as to be sandwiched between the free edges (121, 222) of the plate (120) and of the shell (220), respectively, when said plate and shell are assembled and fastened to each other.

Description

DESCRIPTION Title of the invention: Set of optical modules of a lighting and / or signaling device for a motor vehicle.

[0001] The present invention claims priority from French application 2300892 filed on 31.01.2023, the content of which (text, drawings and claims) is incorporated herein by reference. The invention generally relates to lighting and / or signaling devices for motor vehicles and is more particularly concerned with the assembly of optical module elements of a lighting and / or signaling device, in particular a motor vehicle headlight.

[0002] According to the state of the art, an optical module of a lighting and / or signaling device comprises, in a known manner, at least one light source associated with optical means or components such as lenses, reflectors and others to generate at least one light beam in a determined direction. An optical module is generally contained in a housing which itself belongs to, or is attached to, the housing of a motor vehicle headlight. A headlight may comprise one or more optical modules and in particular three optical modules respectively generating three types of light beams independently or in combination.

[0003] Traditionally, a projection lens of an optical module of a lighting and / or signaling device is attached to the front face of the module housing and closes the housing defined by the inside of the housing. The lens is fixed by screws, clips or staples on the front face of the housing. These fixing elements must be multiplied by as many modules in a projector comprising several optical modules. This leads to additional assembly operations and a cost additional parts and, ultimately, an increased cost price of the projector.

[0004] The invention therefore aims in particular to overcome these drawbacks by proposing a solution making it possible to reduce costs on the one hand, by reducing the number of assembly elements and, on the other hand, by facilitating assembly operations, all the more so when the projector comprises a plurality of optical modules.

[0005] To this end, the invention has as its first object an optical module for a lighting and / or light signaling device of a motor vehicle, said optical module comprising a housing obtained after assembly of a support plate, receiving at least one light source, and a shell defining at least one reflector extending opposite the light source; the housing defining a hollow body comprising an opening on the front face of the housing closed by a projection lens capable of allowing the diffusion of light emitted by said light source towards the outside of the module and cooperating with the reflector to form a determined type of light beam; said lens being shaped to have support interfaces sandwiched, in the front face of the housing, between the free edges respectively of the plate and of the shell when they are assembled and fixed to each other;the fixing of the lens in the housing being ensured solely by the pressure exerted on the support interfaces between the free edges respectively of the plate and the shell.;

[0006] According to one characteristic, the support interfaces of the projection lens comprise lateral extensions formed in one piece with the lens and extending substantially perpendicular to the diffusion plane of the lens.

[0007] According to another characteristic, the lens has a transverse profile in the shape of a “U”; the branches of the corresponding “U” respectively to first and second lateral extensions of the lens extending inside the housing and the straight part connecting the two branches of the “U” corresponding to the diffusion plane of the lens.

[0008] According to another characteristic, the first and second extensions comprise centering means cooperating respectively with complementary centering means arranged on the respective free edges of the plate and the shell.

[0009] According to another characteristic, the free edge of the plate comprises a cavity cooperating with a front centering means of the lens arranged on the first extension, and in which the free edge of the shell comprises a cavity cooperating with a lateral centering means of the lens arranged on the second extension; and support means arranged respectively on either side of the cavity arranged in the free edge of the shell.

[0010] According to another characteristic, the front centering means is a recess made of the same material as the free edge of the first extension, cooperating with the cavity made in the free edge of the plate, of complementary shape, and the lateral centering means is a lug made of the same material as the second extension cooperating with the cavity made in the free edge of the shell, of complementary shape; the support means respectively defining a rib made on either side of the cavity made in the free edge of the shell.

[0011] According to another characteristic, first and second trims are respectively fixed on the plate and on the shell by covering them at least partially, in the vicinity of the front face of the case and outside the case; said first and second trims being arranged and shaped to respectively have free edges extending in projection beyond the lens, outside the lens, so as to respectively mask the lens attachment interfaces inside the housing, for an observer located in front of the module when the latter is mounted in the vehicle; said attachment interfaces comprising the lateral extensions of the lens and their centering and keying means as well as their complementary centering and keying means on the plate, and their complementary centering means and support means on the shell.

[0012] The second subject of the present invention is a method for assembling an optical module as described above, consisting of vertically attaching the first trim to the plate, outside the plate and in the vicinity of the front face of the housing and fixing it to the plate, attaching the lens to the inside of the free edge of the plate by engaging the front centering means of the first extension of the lens in the complementary centering means arranged in the free edge of the plate, vertically attaching the shell to the plate and the lens, to form and close the body of the housing, the free edge of the shell being centered laterally with the second extension of the lens via the lateral centering means of the second extension and the complementary centering means of the shell and taking support via the support means on the second extension, fixing the shell to the plate, and attaching and fixing the second trim to the shell.

[0013] The third subject of the present invention is a lighting and / or signaling device comprising a plurality of adjacent modules as described above, in which the first extensions of the lenses of each module further comprise keying means cooperating respectively with complementary keying means arranged on each plate making it possible to pair each of the lenses with their respective housing.

[0014] The present invention has as its fourth and final object, a motor vehicle comprising at least one lighting and / or signaling device as described above.

[0015] Other characteristics and advantages of the invention will appear on examining the detailed description below, and the attached drawing, in which:

[0016] [Fig.1] illustrates a set of optical modules, according to the invention, seen in perspective;

[0017] [Fig.2] illustrates the set of optical modules of Figure 1 in an exploded view;

[0018] [Fig.3] illustrates the plates of all the optical modules according to the invention, seen in perspective;

[0019] [Fig. 4] illustrates the shells of all the optical modules according to the invention, seen in perspective;

[0020] [Fig.5] illustrates the projection lenses of all the optical modules according to the invention, seen in perspective;

[0021] [Fig.6] illustrates the set of optical modules according to the invention in top view; and

[0022] [Fig.7] illustrates one of the modules of the set of optical modules according to the invention, according to a sectional view along the section axis VII-VII of figure 6.

[0023] In the following, it is considered that the elements represented in the figures are oriented within the same orthonormal XYZ reference frame and identical elements are designated by the same alphanumeric references.

[0024] For this purpose and unless otherwise specified, reference is made to the orthonormal reference frame XYZ to identify the directions of extension which correspond to those of a motor vehicle on which a lighting and / or signaling device is mounted, such as a headlight, according to the invention, and the associated relative notions, including a direction longitudinal (along X), a transverse direction (along Y) and a vertical direction (along Z). The longitudinal direction X extends between the front and rear of the vehicle, the transverse direction Y extends between the right and left lateral sides of the vehicle identified in relation to the driver at the vehicle's driving position, and the vertical direction Z defines the extension of the vehicle in elevation from its rolling plane on the ground. Subsequently, the relative notions front, or frontal, and rear are identified longitudinally, the lateral notion and the relative notions right and left are identified transversely, the notions such as upper and lower or other related relative notions such as low and high, ... are defined vertically in relation to the rolling plane of the vehicle on the ground.

[0025] Figure 1 illustrates a set 10 of three modules 11, 12, 13 identified inside a closed outline in broken lines schematically representing a lighting and / or signaling device 1 and more particularly a vehicle V projector 1 in which said set 10 is installed.

[0026] Each of these three modules 11, 12, 13 participates in one or more lighting and / or signaling functions usually provided by a motor vehicle headlight.

[0027] Figure 2 illustrates the assembly 10 of the three modules 11, 12 and 13 of Figure 1 in an exploded view making it possible to distinguish the different constituent elements of each of the optical modules 11, 12 and 13.

[0028] Each module 11, 12, 13 comprises a housing 101, 102 and 103 whose hollow body defines a housing obtained after assembly of two elements: a plate 110, 120, 130 and a shell 210, 220, 230.

[0029] In the embodiment described, the plates 110, 120 and 130 and the shells 210, 220 and 230 of each of the three modules 11, 12 and 13 are made respectively from a single piece obtained by injection molding, i.e. two parts 100 and 200 which, when assembled together, define the housings 101, 102 and 103 of the three modules 11, 12 and 13.

[0030] The part 100 forming the plates 110, 120 and 130 is hereinafter referred to as the “lower part” and the part forming the shells 210, 220 and 230 is hereinafter referred to as the “upper part”, with reference to their respective positions in FIG. 2; positions which are those of the projector 1 when the latter is mounted in the vehicle V.

[0031] The lower and upper parts 100 and 200 are fixed to each other by means of screws, not shown in Figure 2.

[0032] Each housing 101, 102, 103 has the general shape of a rectangular parallelepiped, defining a hollow housing receiving one or more light sources, such as light-emitting diodes or LEDs (an English acronym for "Light-Emitting Diode"). Such LEDs, SEL, are mounted on a printed circuit board CCI supported by the plates 110, 120, 130 as illustrated schematically in Figure 7 which considers one 12 of the three modules 11, 12, 13 according to a longitudinal section (along X), a figure which will be described below in detail.

[0033] Figure 3 illustrates, in a perspective top view, the lower part 100 which groups together the plates 110, 120 and 130 of the modules 11, 12 and 13 and Figure 4 illustrates, in a perspective bottom view, the upper part 200 grouping together the shells 210, 220 and 230 of the modules 11, 12 and 13.

[0034] The LED(s), SEL, are capable of generating a light beam by reflection of the light rays emitted by the LED(s) SEL on reflectors 201, 202 and 203 arranged respectively in each of the shells 210, 220 and 230 (figures 4 and 7) and which have the shape of one or more parabolic surfaces obtained by molding. with the shell 210, 220 and 230. The light beams are then respectively diffused through the projection lenses 310, 320 and 330 closing the housing 101, 102, 103 at the front of the housing 101, 102, 103.

[0035] As illustrated in Figure 5, each lens 310, 320, 330 comprises first and second lateral extensions 311-312, 321-322, 331-332 formed in one piece with the lens 310, 320, 330 and extending substantially perpendicular to the diffusion plane (YZ plane) of the lens 310, 320, 330.

[0036] The first and second extensions 311-312, 321-322, 331-332 respectively define, in the vicinity of the front face of each housing 101, 102, 103, support interfaces inside the free edges of the plates 110, 120 and 130 and of the shells 210, 220 and 230 and which are held fixedly in a sandwich between their plates 110, 120 and 130 and their respective shells 210, 220 and 230 at the time of assembly and then fixing of the shells 210, 220 and 230 with the plates 110, 120 and 130.

[0037] Thus, the fixing of the lenses 310, 320, 330 in their respective housings 101, 102 and 103 does not require any fixing means such as screws, clips, staples, etc. The fixing is carried out solely by applying pressure to the free edges of the plates 110, 120 and 130 and the shells 210, 220 and 230 on the support interfaces 311-312, 321-322 and 331-332 of the lenses 310, 320, 330.

[0038] Each lens 310, 320, 330 has a transverse profile (XZ plane) in a “U”. The branches of the “U” correspond respectively to the first and second extensions 311-312, 321-322, 331-332 of each lens 310, 320, 330 inside their respective housings 101, 102, 103. They define first and second legs, 311-312, 321-322, 331-332 respectively lower and upper, of cross section of general shape rectangular. The straight part connecting the first and second branches of the “U” corresponds to the diffusion plane of the lens 310, 320 and 330 (plane along YZ).

[0039] Each upper leg 312, 322, 332 comprises a lateral centering means 313, 323, 333 of the lens 310, 320, 330 (figure 5) defining a lug centered on the upper leg 312, 322, 332, made of the same material as the upper leg 312, 322, 332 and extending towards the outside of the lens 310, 320, 330 (along Z). This lateral centering lug 313, 323, 333 cooperates with a cavity of complementary shape, in a half-moon, 213, 223, 233 arranged inside the free edge 212, 222, 232 of the corresponding shell 210, 220, 230 receiving the lens 310, 320, 330, as illustrated in figure 4.

[0040] The profiles of the shells 210, 220, 230 are shaped to adapt to the corresponding profiles of the plates 110, 120 and 130 and to form, once the shells 210, 220, 230 and the plates 110, 120 and 130 are assembled, the housings 101, 102 and 103 of the modules 11, 12 and 13; housings 101, 102 and 103 which are closed on their front face by the lenses 310, 320 and 330.

[0041] The front free edges 212, 222 and 232 of the shells 210, 220, 230 further comprise respectively pairs of support ribs 217, 227, 237 extending perpendicularly to the free edges 212, 222 and 232, on either side of the lateral centering cavities 213, 223, 233. These support ribs 217, 227, 237 participate in maintaining the lenses 310, 320 and 330 in a “sandwich” shape inside their respective housings 101, 102 and 103.

[0042] Each lower leg 311, 321, 331 comprises a front centering means 314, 324, 334 of the lens 310, 320, 330 forming a step integral with the leg 311, 321, 331 and extending transversely (along Y) over the entire width of the end part of the lower leg 311, 321, 331, and downwards (along Z), perpendicular to the lower leg 311, 321, 331 towards the outside of the lens 310, 320, 330. This indentation 314, 324, 334 of rectangular cross section cooperates with a cavity of complementary shape 114, 124, 134, arranged in the corresponding free edge 111, 121, 131 of the plate 110, 120, 130, as illustrated in figure 3.

[0043] The lower part 100 groups together the plates 110, 120, 130 of each of the three modules 11, 12, 13. This part 100 is shaped to define three plates 110, 120 and 130 of generally rectangular shape, adjacent, connected to each other by their large lateral sides while being offset from each other along the three axes X, Y and Z. The small sides of each plate 110, 120 and 130 advance (along X), towards the front, to form promontories on which the transverse centering cavities 114, 124 and 134 are arranged receiving the indentations 314, 324 and 334 of the lower legs 311, 321 and 331 of the lenses 310, 320 and 330.

[0044] The lateral edges of the lower legs 311, 321 and 331 further comprise keying means 315-316, 325-326 and 335-336 forming notches and / or studs arranged in the thickness of the legs 31, 321 and 331 and / or in the lateral edge(s) of the steps 314, 324 and 334.

[0045] The keying means 315-316, 325-326 and 335-336 of the lenses 310, 320 and 330 cooperate with complementary keying means 115-116, 125-126 and 135-136 arranged around the cavities 114, 124 and 125 of the plates 110, 120 and 130.

[0046] The keying means 315-316, 325-326 and 335-336 are specific to each lens 310, 320 and 330: they are different from one lens to another. They allow the lenses 310, 320 and 330 to be paired with their respective modules 11, 12 and 13 without the risk of incorrect assembly at the time of assembly of lenses 310, 320 and 330 on their respective plates 110, 120 and 130.

[0047] Figure 6 illustrates the assembly 10 of the three modules 11, 12 and 13 in a top view and Figure 7 illustrates a longitudinal sectional view (along X) along the section axis VII-VII of Figure 6.

[0048] In Figure 6, the three optical modules 11, 12 and 13 are completely assembled with the various visible fixing screws of the shells 210, 220 and 230 on their respective plates 110, 120 and 130.

[0049] Covering elements of the housings 101, 102 and 103, designated by trims respectively, lower 410, 420 and 430 and upper 510, 520 and 530 are respectively attached to the plates 110, 120 and 130 and the shells 210, 220 and 230 of the modules 101, 102 and 103. The lower trims 410, 420 and 430 are attached vertically under the plates 110, 120 and 130 then fixed by screws, under the plates 110, 120 and 130 as illustrated in figure 7.

[0050] The upper trims 510, 520 and 530 are attached in a frontal direction, respectively, from the front to the rear of the modules 11, 12 and 13, being guided on the edges of the side walls of the respective lower trims 410, 420 and 430 until they are fixed on their respective shells 210, 220 and 230 by clipping means 211, 511 and 221, 521 and 231, 531, arranged respectively on the upper surfaces of the shells 210, 220 and 230 and on the upper trims 510, 520 and 530.

[0051] Figure 7 considers the central module 12 of the three modules 11, 12 and 13, according to a sectional view along the section line VII-VII of figure 6.

[0052] What is described below with reference to the central module 12 applies to the other two modules 11 and 13 of the set of modules 11, 12 and 13.

[0053] The free edges 421, 522 of the lower and upper trims 420, 520 respectively are shaped and arranged so as to mask the technical parts present inside the housing 102 as well as the fixing interfaces Z12 and Z22 of the lens 320 between the plate 120 and the shell 220, for an observer placed in front of the projector 1 when the latter is mounted on the vehicle V.

[0054] The free edge 421 of the first trim 420 (lower trim) extends beyond the lens 220 to form a lower lip that “licks” the lower edge of the lens 320 and the free edge 522 of the second trim 520 (upper trim) extends beyond the lens 320 to form a visor above the upper edge of the lens 320. The end portions of the free edges 421, 522 belonging respectively to the lower and upper trims 420, 520 are curved towards the lens 320 so as to stiffen the end portions and “blunt” the latter.

[0055] The fixing interfaces Z12 and Z22 thus masked, comprise the legs 321 and 322 of the lens 320 and their centering means 323, 324 and coding means 325 and 326 (which do not appear in Figure 6 but in Figure 5) as well as their complementary centering means 124, coding means 125, 126 on the plate 120, and their complementary centering means 223 and the support ribs 227 on the shell 220. The support ribs 227 do not appear in Figure 6 but appear in Figure 4.

[0056] These interfaces Z12 and Z22 have their counterparts in the other two modules 11 and 13, respectively, Z11, Z21 and Z13, Z23 (as illustrated in figures 3 and 4). The lower 410, 430 and upper 510, 530 trims, corresponding respectively to the other modules 11 and 13, are shaped and arranged to mask in the same way the technical parts and the legs of the lenses with their respective centering and keying means, for a observer placed in front of projector 1 when the latter is mounted on vehicle V.

[0057] The lower trims 410, 420 and 430 and the upper trims 510, 520 and 530 can be made respectively in a single piece 400, respectively 500, obtained by an injection molding process, as for the plates, 100, 120 and 130 (lower piece 100) and the shells 210, 220 and 230 (upper piece 200). Thus, the assembly 10 of the three modules 11, 12 and 13 according to the invention can be made from the assembly of only four pieces 100, 200, 400 and 500 and the three lenses 310, 320 and 330.

[0058] The assembly of the different parts is thus simplified with a reduced number of assembly operations respecting a precise assembly order as described below considering a 12 of the optical modules 11, 12 and 13.

[0059] The assembly method according to the invention of the optical module 12 consists of vertically attaching the first trim 420 to the plate 120, outside the plate 120 and in the vicinity of the front face of the housing 102 and fixing it to the plate 120 by screws.

[0060] It then consists of bringing the lens 120 inside the free edge 121 of the plate 120 by engaging the front centering means 324 of the first extension 321 of the lens 320 in the complementary centering means 124 arranged in the free edge 121 of the plate 120.

[0061] It then consists of vertically attaching the shell 220 to the plate 120 and the lens 320, to form and close the body of the housing 102.

[0062] The free edge 222 of the shell 220 is centered laterally with the second extension 322 of the lens 320 via the lateral centering means 323 of the second extension 322 and the complementary centering means 223 of the shell 220.

[0063] The free edge 222 of the shell rests, via the support ribs 227, on the second extension 322.

[0064] The process then consists of fixing the shell 220 on the plate 120 and finally, of attaching and fixing the second trim 520 on the shell 220 by screws.

[0065] The assembly method, respecting the same assembly order, is identical with regard to the assembly of the optical modules 11, 12 and 13 of the assembly 10; the lenses 310, 320 and 330 being moreover paired with their respective housings 101, 102 and 103.

Claims

CLAIMS 1. Optical module (12) for a lighting and / or light signaling device (1) of a motor vehicle (V), said optical module (12) comprising a housing (102) obtained after assembly of a support plate (120) receiving at least one light source (SEL) and a shell (220) defining at least one reflector (202) extending opposite the light source (SEL); the housing (102) defining a hollow body comprising an opening on the front face of the housing (102) closed by a projection lens (320) capable of allowing the diffusion of light emitted by said light source (SEL) towards the outside of the module (12) and cooperating with the reflector (202) to form a determined type of light beam;said lens (320) being shaped to have support interfaces (321, 322) sandwiched, in the front face of the housing (102), between the free edges (121, 222) respectively of the plate (120) and of the shell (220) when they are assembled and fixed to each other; the fixing of the lens (320) in the housing (102) being ensured solely by the pressurization of the support interfaces (321, 322) between the free edges (121, 222) respectively of the plate (120) and of the shell (220).; 2. Optical module (12) according to the preceding claim, in which the support interfaces (321, 322) of the projection lens (320) comprise lateral extensions formed in one piece with the lens (320) and extending substantially perpendicular to the diffusion plane of the lens (320).

3. Optical module (12) according to one of the preceding claims, in which the lens (320) has a transverse “U” shaped profile; the branches of the “U” corresponding respectively to first and second lateral extensions (321, 322) of the lens. (320) extending inside the housing (102) and the straight part connecting the two branches of the “U” corresponding to the diffusion plane of the lens (320).

4. Optical module (12) according to the preceding claim, in which the first and second extensions (321, 322) comprise centering means (324, 323) cooperating respectively with complementary centering means (124, 223) arranged on the respective free edges (121, 222) of the plate (120) and of the shell (220).

5. Optical module (12) according to the preceding claim, in which the free edge (121) of the plate (120) comprises a cavity (124) cooperating with a front centering means (324) of the lens (320) arranged on the first extension (321), and in which the free edge (222) of the shell (220) comprises a cavity (223) cooperating with a lateral centering means (323) of the lens (320), arranged on the second extension, and support means (227) arranged respectively on either side of the cavity (223) arranged in the free edge (222) of the shell (220).

6. Optical module (12) according to the preceding claim, wherein the front centering means (324) is a recess formed in one piece with the free edge of the first extension (321), cooperating with the cavity (124) formed in the free edge (121) of the plate (120), of complementary shape, wherein the lateral centering means (323) is a lug formed in one piece with the second extension (322) cooperating with the cavity (223) formed in the free edge (222) of the shell (220), of complementary shape; the support means (227) respectively defining a rib formed on either side of the cavity (223) formed in the free edge (222) of the shell (220).

7. Optical module (12) according to claims 1 to 6, wherein first and second trims (420, 520) are respectively fixed on the plate (120) and on the shell (220) by covering them at least partially, in the vicinity of the front face of the housing (102) and outside the housing (102); said first and second trims (420, 520) being arranged and shaped to respectively have free edges (421, 522) extending projecting beyond the lens (320), outside the lens (320), so as to respectively mask the fixing interfaces (Z12, Z22) of the lens (320) inside the housing (102), for an observer located in front of the module (12) when the latter is mounted in the vehicle (V);said fixing interfaces (Z12, Z22) comprising the lateral extensions (321, 322) of the lens (320) and their centering means (323, 324) and keying means (325, 326) as well as their complementary centering means (124), keying means (125, 126) on the plate (120), and their complementary centering means (223) and support means (227) on the shell (220).; 8. Method for assembling an optical module (12) according to the preceding claims, said method consisting of vertically attaching the first trim (420) to the plate (120), outside the plate (120) and in the vicinity of the front face of the housing (102) and fixing it to the plate (120), attaching the lens (120) inside the free edge (121) of the plate (120) by engaging the front centering means (324) of the first extension (321) of the lens (320) in the complementary centering means (124) arranged in the free edge (121) of the plate (120), vertically attaching the shell (220) to the plate (120) and the lens (32), to form and close the body of the housing (102), the free edge (222) of the shell (220) being centered laterally with the second extension (322) of the lens (320) via the lateral centering means (323) of the second extension (322) and the complementary centering means (223) of the shell (220) and by taking support via the support means (227) on the second extension (322), to fix the shell (220) on the plate (120) and, to report and fix the second trim (520) on the shell (220).

9. Lighting and / or signaling device (1) comprising a plurality of adjacent modules (11, 12, 13), according to one of claims 1 to 7, in which the first extensions (311, 321 and 331) of the lenses (310, 320 and 330) of each module (11, 12 and 13) further comprise keying means (315-316, 325-326, 335-336) cooperating respectively with complementary keying means (114-115, 124-125, 134-135) arranged on each plate (110, 120, 130) making it possible to pair each of the lenses (310, 320 and 330) with their respective housing (101, 102 and 103).

10. Motor vehicle (V) comprising at least one lighting and / or signaling device (1) according to the preceding claim.

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