A module of at least two components of a vehicle headlamp

Abstract

A module of at least two components of a vehicle headlamp, wherein one (4) of the components has at least one locating pin (30) comprising a pillar (22) with plastically deformable outer lateral thickness (26) around the pillar, while another one (5) of the components has a locating orifice (31), and wherein the outer lateral thickness (26) is configured to deform plastically and rest against the orifice (31) when inserted into said orifice, thereby forming a firm abutment that keeps the pillar (22) centred inside the orifice (31).

Description

FIELD OF THE INVENTION

[0001] The technical field of the invention is the field of vehicle light modules of the type comprising at least one light source holding part and one primary optics assembled in a position relative to each other defined by positioning pins and holes.BACKGROUND OF THE INVENTION

[0002] It is known to assemble several components, such as a light source holding part, a primary optic, a holder, a secondary optic, and so on, to manufacture a vehicle's light module. Components are positioned relative to each other by reference points located on some of the parts.

[0003] For the assembly, some parts are pre-assembled together because their mutual positioning is crucial to the operation of the light module. A light source holding part and primary optics unit need to be accurately positioned for an efficient first treatment of the light rays related to the light source. Similarly, a primary optics unit and a secondary optics unit need accurate referencing. It is also a common practice to preassemble some of these parts together before including them in a stack of components forming the light module.

[0004] US11668446B2 discloses a motor vehicle's light module for lighting or signalling device purposes that includes at least one light source mounted on a support, an optical unit that engages the light source that forms a light beam and a locating system, which includes at least one locating pin inserted into a locating orifice. The support contains at least one locating pin and locating orifice, while the optical unit has the other locating pin and locating orifice. The locating pins include two facing parts where one of the parts is identified as the rigid part, and the other of the parts is identified as the flexible part, where one part is more rigid than the other of the two facing parts.

[0005] This suggested solution helps to improve the accuracy of the positioning of a light source, held by the PCB board, relative to the optical unit, while guaranteeing assembly of the PCB board on the optical unit.

[0006] A drawback of this known pin-orifice arrangement is that the elastic part prevents from providing a safe control of geometry. Moreover, the diameter of the elastic pin is rather large because of limitations in the tooling of the pin. This leads to space consumption on the PCB board, a feature which is not compatible with the trend of compacting headlamps to integrate into stylistic face designs.SUMMARY OF THE INVENTION

[0007] An object of the invention is a module of at least two components of a vehicle headlamp, one of said components being an optical unit (primary optic in the example, reflector system in the non-represented alternative) and the other component being selected in the list consisting of: a light source holding part, a holder, wherein one of the components has at least one locating pin comprising a pillar having a plastically deformable outer lateral thickness around the pillar, while another one of the components has a locating orifice, and wherein said outer lateral thickness is configured to deform plastically and rest against the orifice when inserted into said orifice, thereby forming a firm abutment that keeps the pillar centred inside the orifice.

[0008] The light source holding part can be a printed circuit board (PCB) that is configured to securely position a light source within an optical unit of a vehicle headlamp module.

[0009] In other words, the advantage of the outer lateral thickness is to offer a better controllable geometry because the pin has no elements working as a spring. The deformation of the outer lateral thickness is plastic. This increases the position accuracy in the assembly because no balance of elastic strengths is at stake regarding the stability of the position.

[0010] According to the invention, the design of the locating pins and orifices allows a controlled geometry without elastic parts or additional machinery required during assembly.

[0011] In addition, the overall dimensions of one pin according to the invention are minimal, compared to those of a pin comprising a spring part, because of limitations in the tooling of the spring part. This leads to less space consumption on the light source holding part. Another advantage is the absence of additional components and machinery necessary. One known alternative to achieve high accuracy between the optics and the light source holding part is to actively align these parts with a robot, then glue it and harden it in the correct position. So, glue, machinery to dispense glue, position the part and UV hardening is not necessary either.

[0012] In one embodiment, at least one locating orifice is located on the light source holding part and one corresponding locating orifice is located on the optical unit.

[0013] In another embodiment, at least one locating pin is located on the holder and one corresponding locating orifice is located on the optical unit.

[0014] These two embodiments can be combined together, with the optical unit having at least one locating orifice and at least one locating pin.

[0015] In one embodiment, the outer lateral thickness of a locating pin has a decreasing diameter from bottom to top along the pillar. This change in diameter helps inserting the pin in the orifice. The outer lateral thickness can be divided into a lower portion that can be conical (decreasing diameter) or prismatic (constant diameter) and an upper portion that is conical.

[0016] In one embodiment, the outer lateral thickness consists of excrescences protruding from the pillar.

[0017] On a first single locating pin, the excrescences can be arranged to achieve self-centring, allowing precise centring in a corresponding hole during assembly. This design enables rotation of the components around an axis defined by the first locating pin's position, ensuring accurate alignment of the two components.

[0018] On a second locating pin, the excrescences, preferably located symmetrically relative to a direction joining the first and second locating pins, are arranged so as to achieve self-positioning perpendicularly to said direction, allowing for precise positioning in a corresponding hole during assembly. This other locating pin defines the angular position of the components, whereas the first locating pin defines the centre of rotation between the two components.

[0019] To ensure uniform deformation upon insertion, excrescences may be designed as thin-walled structures (0.1-2 mm thick) with controlled injection-moulding processes to minimize material defects or irregularities on the surface of the prismatic pillar.

[0020] In this embodiment, the cross-section dimension of the pillar is smaller than that of its corresponding orifice by at least 0.1 mm.

[0021] In another embodiment, the outer lateral thickness consists of a continuous thickness surrounding the pillar. No clear boundary between the pillar and the lateral outer thickness is required in this case. The pillar can be made of the same material as the outer lateral thickness. Of course, the pillar can also be made of a different material, for instance though over moulding the outer lateral thickness on the pillar.

[0022] In one embodiment, the module comprises a light source mounted on the light source holding part and engaging with the optical unit for forming a beam of light.

[0023] The holder may be manufactured using various materials that match or differ from those used in other parts within the headlamp module. For instance, it may consist entirely of plastic with optimized excrescence shapes and sizes configured to achieve desired levels of deformability while maintaining mechanical strength.

[0024] Additional connections such as snap-fit connections or clips or heat-deformable pins or screws may also provide security to fix the parts together in the correct position provided by the location pins. During installation additional pins can provide pre-guiding and / or proper stacking before or after engaging the locating pins into their respective orifices. However, additional connections, when used, should not alter the positioning of the two parts set by the cooperation of the locating pins and locating orifices. Should the components comprise additional security measures for enhanced stability during installation, they could still implement the location pins and orifices of the invention. For instance, clips may serve as a secondary locking mechanism to prevent accidental disassembly or misalignment between components before the headlamp housing is entirely assembled.

[0025] In some embodiments, the locating pins may have diameters ranging from 1 mm to 6 mm for use in compact designs where space is limited. The material selection for these locating pins should consider factors such as thermal stability, mechanical strength, and optical properties; however, it may be advantageous if made of the same material as its corresponding component.

[0026] To ensure sufficient plastic deformation without compromising structural integrity during assembly, design optimization techniques may involve optimizing excrescence shape and size to achieve desired levels of plastic deformability while maintaining mechanical strength.

[0027] Standard orifice shape is cylindrical or an oblong hole. In some embodiments, the location orifices may have conical shapes (i.e., triangular axial cross-sections) that mirror the shape of excrescences on corresponding pins. This design ensures a snug fit and precise positioning during assembly. In other cases, locating orifices may be designed with rounded edges to facilitate smooth insertion of prismatic pillars without compromising their structural integrity.

[0028] Furthermore, locating orifices may also incorporate features to facilitate easy insertion of prismatic pillars during assembly processes. For instance, a slight chamfer on the edge of an orifice may aid in guiding pins into position while minimizing resistance forces required for installation. Conversely, small ridges within the orifice may provide additional grip points when removing pins from their respective holes.

[0029] The invention also provides means for dealing with thermal expansion of materials. When the materials of components are different, their different coefficients of thermal expansion (CTE) cause dimensional variations between the components. For small components, such variations can be absorbed by the elasticity of the material. However, for large components, cracks can occur. CTE compensation is therefore essential.

[0030] In a particular embodiment, one of the locating pins is dimensioned such that it does not plastically deform in the locating aperture to enable CTE compensation. Depending on the dimensions of the components, such compensation may be desirable to prevent stress from being transferred to the components as a result of temperature changes when both locating pins are locked.

[0031] The module of the invention may be pre-assembled before being integrated into the headlamp module or other assemblies within larger systems.

[0032] Another object of the invention is a vehicle headlamp comprising a module of at least two components positioned relative to each other in precise alignment. This allows for precise positioning during assembly without compromising optical performance. The absence of elastic parts in these designs eliminates concerns about balance between spring forces and ensures a safe control over geometry.

[0033] Another object of the invention is a vehicle equipped with a vehicle headlamp as described above.BRIEF DESCRIPTION OF THE FIGURES

[0034] The invention will be better understood upon reading the non-limiting examples disclosed hereafter. The terms "top," "bottom," "front" and "rear" refer to the directions once the light projection system is installed on a vehicle. The X, Y and Z directions are used in accordance with the relevant standards. The X direction is longitudinal, parallel to the direction of travel of the vehicle. The Y direction is transverse, i.e. horizontal and perpendicular to the direction of travel. The Z direction is vertical. The following description is with reference to the attached drawings in which: [Fig. 1] is a side exploded view of an assembly of a heat sink, a printed circuit board, a primary optics unit, a cut-off shield, a holder, a secondary optics unit. [Fig. 2] shows, in perspective, the holder. [Fig. 3] shows, in perspective, the cut-off shield. [Fig. 4] shows, in perspective, the primary optics unit. [Fig. 5] shows, in perspective, the printed circuit board. [Fig. 6] shows, in perspective, the heat sink. [Fig. 7] is like [Fig. 2] and shows the components holder and cut-off shield assembled. [Fig. 8] is like [Fig. 7] and shows the previous components with the primary optics unit assembled therewith. [Fig. 9] is like [Fig. 8] and shows the previous components with the printed circuit board assembled therewith. [Fig. 10] is like [Fig. 9] and shows the previous components with the heat sink assembled therewith. [Fig.11] is a close-up view of part XI of [Fig. 2] or part XI of [Fig. 4]. [Fig.12] is an axis view of [Fig. 11] of a three-excrescences locating pin. [Fig.13] is a view similar to [Fig. 12] of a two-excrescences locating pin. [Fig.14] is similar to [Fig. 13] and illustrates a locating pin in a locating orifice in an alternative embodiment. [Fig.15] is similar to [Fig. 13] and illustrates an alternative embodiment. [Fig.16] is similar to [Fig. 13] and illustrates an alternative embodiment. [Fig.17] is similar to [Fig. 13] and illustrates an alternative embodiment. [Fig.18] is a face view of a printed circuit board in an alternative embodiment. [Fig. 19] is a perspective view of a continuous outer layer first locating pin according to another embodiment before plastic deformation. [Fig. 20] is a perspective view of the first locating pin of [Fig. 19] and corresponding locating orifice after plastic deformation. [Fig. 21] is a perspective view of a continuous outer layer first locating pin according to another embodiment before plastic deformation. [Fig. 22] is a perspective view of the first locating pin of [Fig. 21] and corresponding locating orifice after plastic deformation. [Fig. 23] is a perspective view of a continuous outer layer second locating pin and corresponding oblong locating orifice according to another embodiment after plastic deformation. [Fig. 24] is a perspective view of a continuous outer layer second locating pin and corresponding oblong locating orifice according to another embodiment after plastic deformation. DETAILED DESCRIPTION

[0035] The assembly represented in Fig. 1 comprises, from left to right in the figure, a secondary optics unit 1, a holder 2, a cut-off shield 3, a primary optics unit 4, a printed circuit board 5 - sometimes referred to as PCB - and a heat sink 6. Other lighting system components can be added to this assembly, such as filters, a protective bulb, etc. They are not represented here because they are unnecessary to explain the invention.

[0036] The example headlamp module is a simple bi-function module with low-beam and high-beam.

[0037] The holder 2 is a first component. It is an elongated object with a rectangular cross-section, featuring a longitudinal wall 7 that extends between a front face 8 and a rear face 9. The front face 8 is specifically designed to support the secondary optics unit 1. Adjacent to the longitudinal wall 7 are two opposing recesses 10 open to the rear face 9. Second inserted component, the cut-off shield 3 is placed within these recesses 10, ensuring proper positioning within the holder 2.

[0038] The rear face 9 of the holder 2 includes a peripheral flange 11 that extends perpendicularly to the longitudinal wall 7. Various moulded shapes are defined on the rear face 9, primarily for mechanical reinforcement, though only those pertinent to the invention will be explained.

[0039] The flange 11 is equipped with fixation means 12 that allow the holder 2 to be attached to a (non-represented) holder frame in the also non-represented housing of the headlamp.

[0040] Additionally, the flange 11 contains four long stacking pins 13, intended to maintain the components carried by the holder 2 in a stacked arrangement. Stacking pins 13 help pre-guide and stack all the assembly components from the holder 2 to the heat sink 6. These stacking pins 13 are cylindrical with a small draft angle and chamfer on the top 32. The components have stacking holes 14 slightly larger in diameter than the stacking pins 13, allowing for a loose fit that ensures preliminary positioning on the holder 2 while permitting more precise positioning by other means.

[0041] Near two of the four stacking pins 13 on the flange 11, there are two locating pins 15a and 15b (globally referred to as 15) for the primary optics unit 4. The close-up view of Fig. 11 shows more details on pins 15.

[0042] The primary optics unit 4 is a third component. As shown in Fig. 4, it comprises two rows of lenses 16. Each lens 16 is dedicated to an LED light source mounted on the printed circuit board 5. The rows of lenses 16 are located in a recess 17 of the primary optics unit 4, with their coupling faces 18 facing the printed circuit board 5. Annular bosses 19 around each stacking hole 14 on the front face of primary optics unit 4 define a reference surface for the positioning of the primary optics unit 4 on the holder 2.

[0043] Two lateral faces 20 have each two stacking holes 14 and a locating orifice 21a, 21b (globally referred to as 21) corresponding to the holder's locating pins 15a and 15b. One of them 21a has a circular cross-section. The other one 21b has an oblong cross-section.

[0044] As best shown in Figures. 11, 12 and 13, each locating pin 15,30 comprises a prismatic pillar 22 and an outer lateral thickness consisting of peripheral excrescences 23. The pillar 22 has a constant cross-sectional area, while the excrescences 23 are distributed around the pillar 22. In another (non-represented) embodiment, the pillar 22 has a small draft angle. There can be a handful of excrescences 23. In the example, two or three excrescences 23 occupy a conical volume around the pillar 22 that decreases in diameter from the bottom to the top of the pillar 22. A lower portion 24 comprises a cylindrical face, below an upper portion 25 comprising a taper to facilitate insertion. Excrescences 23 protrude from each pillar's lateral side 26. All the excrescences 23, considered individually, are identical in the present embodiment.

[0045] On the pillar 22 of first pin 15a, three excrescences 23 are regularly spaced.

[0046] Two excrescences 23 are diametrically opposed on the pillar 22 of the second pin 15b. Their location on the pillar 22 is symmetrical relative to the direction 27 joining the two pillars 22, or more precisely, relative to a plane 28 containing the axis of the two pillars 22, as shown in Fig. 4.

[0047] Each locating pin 15 is surrounded by a depression 29 at its bottom to free the portion of the excrescences 23 that is expected to deform plastically during insertion into an orifice. This avoids that the primary optics 4 is being blocked before reaching its dedicated final position in the X direction.

[0048] The locating orifices 21a and 21b on the primary optics unit 4 have a diameter greater (the smaller dimension of the opening when the cross-section is not circular) than the diameter of the conical volume occupied by the excrescences 23 at the top of the pillar 22 but smaller at the base. Thus, when a locating pin 15 enters a locating orifice 21, the excrescences 23 contact the orifice wall and prevent full insertion unless sufficient force is applied to deform the excrescences 23. If the pressing force is adequate, the excrescences 23 plastically deform around the pillar 22, allowing deeper insertion into the locating orifice 21. Displaced material flows in the gap between the orifice and the pillar 22 by the deformed excrescences 23, eliminating any movement of the pillar 22 within the orifice.

[0049] Thanks to the self-centring effect of the three excrescences 23 of the first locating pin 15a inside the first circular locating orifice 21a, the relative positioning of the holder 2 with the primary optics unit 4 is set without any play. Thus, only the angular position of the two components needs to be set. The second locating pin 15b and oblong locating orifice 21b ensure this angular position thanks to the two excrescences 23 that rest against the second orifice without any play after plastic deformation.

[0050] When the primary optics unit 4 is placed over the stacking pins 13, it is roughly positioned on the holder 2. The locating pins 15 align with the locating orifices 21 and are ready for insertion. Pushing the primary optics unit 4 against the holder 2 causes the locating pins 15 to engage with the locating orifices 21, precisely positioning the primary optics unit 4 through self-centring. If the pushing force is sufficient, the excrescences 23 plastically deform, and the primary optics unit 4 is precisely positioned on the holder 2. This adequate force can be applied during the initial positioning of the primary optics unit 4, when assembled along with the holder 2, or later when all components are stacked, and the stack is tightened with (non-represented) clamping means that traversing the entire stack.

[0051] The primary optics unit 4 also features two locating pins 30a and 30b (globally referred to as 30) on its rear face, designed to cooperate with two locating orifices 31a-31b (globally referred to as 31) on the printed circuit board 5 (PCB). Annular bosses 19 around each stacking hole 14 on the rear face of primary optics unit 4 define a reference surface for the positioning of the printed circuit board 5 on the primary optics unit 4.

[0052] A fourth component is the printed circuit board (PCB) 5. The PCB has four stacking holes 14 that engage with the four stacking pins 13 on the holder 2, allowing for a loose fit that ensures preliminary positioning of the PCB on the primary optics unit 4 without imposing precise positioning.

[0053] The PCB also has its two locating orifices 31a-31b that align with the locating pins 30a and 30b of the primary optics unit 4 after preliminary positioning by the long stacking pins 13. The locating orifices 31a-31b have a circular cross-section.

[0054] Similarly to pins 15, the locating pins 30 also comprise a pillar 22 and peripheral excrescences 23 designed to deform plastically. When the PCB is pushed against the primary optics unit 4, the self-centring of the pin 30a in the locating orifice 31a ensures precise positioning of the PCB on the primary optics unit 4. Thus, only the angular position of the two components needs to be set. The second locating pin 30b and locating orifice 31b ensure this angular position thanks to the two excrescences 23 that rest against the second locating orifice 31b without any play after plastic deformation.

[0055] Each locating pin 30 is surrounded by a depression 29 at its bottom to free the portion of the excrescences 23 that is expected to deform plastically during insertion into an orifice. This avoids that the PCB is being blocked before reaching its dedicated final position in X direction.

[0056] The locating orifices 31a and 31b on the printed circuit board 5 have a diameter greater than the diameter of the conical volume occupied by the excrescences 23 at the top of the pillar 22 but smaller at the base. Thus, when a locating pin 30 enters a locating orifice 31, the excrescences 23 contact the orifice wall and prevent full insertion unless sufficient force is applied to deform the excrescences 23. If the pressing force is adequate, the excrescences 23 plastically deform around the pillar 22, allowing deeper insertion into the locating orifice 31. Displaced material flows in the gap between the orifice and the pillar 22 by the deformed excrescences 23, eliminating any movement of the pillar 22 within the orifice.

[0057] Thanks to the self-centring effect of the three excrescences 23 of the first locating pin 30a inside the first circular locating orifice 31a, the relative positioning of the printed circuit board 5 with the primary optics unit 4 is set without any play. Thus, only the angular position of the two components needs to be set. The second locating pin 30b and circular locating orifice 31b ensure this angular position thanks to the two excrescences 23 that rest against the second orifice without any play after plastic deformation.

[0058] When the printed circuit board 5 is placed over the stacking pins 13, it is roughly positioned on the primary optics unit 4. The locating pins 30 align with the locating orifices 31 and are ready for insertion. Pushing the printed circuit board 5 against the primary optics unit 4 causes the locating pins 30 to engage with the locating orifices 31, precisely positioning the printed circuit board 5 through self-centring. If the pushing force is sufficient, the excrescences 23 plastically deform, and the printed circuit board 5 is precisely positioned on the primary optics unit 4. This adequate force can be applied during the initial positioning of the printed circuit board 5, when assembled along with the primary optics unit 4, or later when all components are stacked, and the stack is tightened with (non-represented) clamping means that traversing the entire stack.

[0059] Finally, the heat sink 6 is placed on the PCB as a fifth component. It is stacked and positioned by the long stacking pins 13 at a position considered sufficient since the heat sink 6 does not contribute to the light beam production. It only needs to have intimate contact with the PCB to dissipate heat.

[0060] Once the stack is formed and the locating pins 15 and 30 are forcefully inserted into the locating orifices 21 and 31, either by a final clamping tool or progressively during the positioning of the components, the stack must be maintained in its final position. For this purpose, the tips 32 of the long stacking pins can be riveted - i.e., heated and deformed to form heads that prevent the components from sliding off the long stacking pins 13. Screwing, clamping or alternative fixing methods are also possible.

[0061] Thanks to the self-centring effect of the excrescences 23 of the locating pins 15 and 30 inside the locating orifices 21 and 31, the positioning of the components, i.e. the holder 2 with the primary optics unit 4 and the primary optics unit 4 with the printed circuit board 5, is set without any play.

[0062] Only manufacturing tolerances can affect the exact positioning of the two components relative to each other. In this embodiment, tolerance of size and position of the pillar 22 are as follows.

[0063] The diameter of the pillars 22 may range from 0,8 mm to 6 mm, with optimal sizes varying depending on specific application requirements.

[0064] The prismatic pillars 22 may be configured to have varying diameters ranging from 0,8 mm to 6 mm or more, depending on the specific dimensions of each part. In this example, only two locating pins 15, 30 are sufficient for positioning a pair of components. The pillars 22 can also contain a draft angle. With a bigger printed circuit board 5, more locating pins may be necessary.

[0065] Pressing the primary optics unit 4 against the holder 2 and the printed circuit board 5 against the primary optics unit 4 can take place either when the two components of a pair are joined, or later in the assembly process when all the stacked components are pressed together. In both cases, the shape of the locating pins 15, 30 ensures self-centring.

[0066] In another embodiment shown in Fig. 18, the referencing system can be split into two portions - one for the Y direction and one for the Z direction. An example is the PCB 33 that can have one locating orifice 34 dedicated to positioning in a first direction and two positioning orifices 35 dedicated to positioning in a second direction, perpendicular to the first direction. In this embodiment, only the design of pins 15b, 30b with two excrescences is used. Locating orifices 34 and 35 can have an oblong cross-section to allow CTE compensation.

[0067] This may be also useful when the PCB needs to be larger. For instance, if the PCB extends widely in the Y direction on the vehicle, three sets of locating pins and locating orifices can be provided, for instance, one at each end of the PCB for precise locating in the Z direction and one in the middle of the PCB for precise location in the Y direction.

[0068] In another embodiment, the optic component, which has to be positioned precisely on a PCB board with LEDs, can be a reflector system instead of a primary 4 or secondary 1 optics unit. The skilled person can easily apply to a reflector system the solution of locating pins 30 and locating orifices 31 described here for a primary optics unit 4 and a PCB 5. Locating pins will be applied to the reflector system. Orifices will stay on the PCB.

[0069] In Figs. 14-17, four variants are illustrated for the design of the combination between the parts (locating pin and locating orifice). For the second pin 15b, 30b responsible for the axis definition, several options are possible. The first one 15a, 30a, responsible for the rotating point, remains unchanged. These variants show how a difference in the coefficient of thermal expansion (CTE) between materials can be compensated.

[0070] In the first option, illustrated in Fig. 14, no deformation of the pin 15b is designed. The excrescences 23 of the pin 15b can move freely in the given play defined by the excrescences and the dimensions of the oblong cross-section orifice 21b.

[0071] In the second option, illustrated in Fig. 15, a pin 15b deformation is designed, with the possibility to move along the axis of the oblong cross-section orifice 21b without play.

[0072] In the third option, illustrated in Fig. 16, no pin 15b deformation is designed to allow CTE compensation on a smaller scale between the circular cross-section orifice 21b and the excrescences 23 of the pin, compared to the first option.

[0073] The second pin defines only the axis, so the accuracy is not that critical compared to the accuracy needs of the first pin. Here is the calculation for the 1 st< (for the smaller dimension of the opening when the cross-section is not circular) and 3rd options:

[0074] For the locating pin and orifice with three excrescences, providing the main reference: orifice diameter: 3mm + / -0.05 excrescences diameter: 3,1mm +-0.05

[0075] The main reference locating pin and orifice are removing two degrees of freedom. Only the rotation remains possible.

[0076] For the locating pin and orifice, with two excrescences, providing the secondary reference: orifice diameter: 3mm + / -0.05 excrescences diameter: 2.9mm +-0.05

[0077] When the excrescences diameter is minimal, and the orifice diameter is maximal, a small rotation movement of + / -0.1mm in the Z direction is possible.

[0078] This small movement allows for compensating thermal expansion during thermal load without having a critical impact on the positioning tolerance.

[0079] In the fourth option, illustrated in Fig. 17, the pin 15b is designed to plastically deform. No CTE compensation is implemented.

[0080] In the embodiment of [Fig. 19] and [Fig. 20], the locating pin 36 of the holder 2' has a pillar 22 surrounded by a continuous outer lateral thickness 37, instead of three excrescences. Here, the delimitation shown in dotted line between pillar 22 and continuous outer lateral thickness 37 is theorical, unless a different material is used for each, which is not a requirement of the invention.

[0081] Said continuous outer lateral thickness 37 is plastically deformable.

[0082] When the locating orifice 21a of the primary optics unit 38 is pressed around the locating pin 36, the continuous outer lateral thickness 37 is deformed as shown in [Fig. 20], where a deformed region 39 appears at the bottom of the continuous outer lateral thickness 37.

[0083] Similarly, on the primary optics unit 38, the locating pin 40 of [Fig. 21] and [Fig. 22] comprises a pillar 22 surrounded by a continuous outer lateral thickness 41 instead of three excrescences. The continuous outer lateral thickness 41 is divided in two parts: a cylindrical lower portion 42 and a conical upper portion 43.

[0084] Here again, the delimitation shown in dotted line between pillar 22 and continuous outer lateral thickness 41 is theorical.

[0085] As shown in [Fig. 22], when the locating orifice 31a of the printed circuit board 44 is pressed around the locating pin 40, a deformed region 45 appears at the bottom of the continuous outer lateral thickness 41. The deformed region 45 of the continuous outer lateral thickness 41 extends over the lower portion 42 and part of the upper portion 43.

[0086] In the embodiments of [Fig. 23] and [Fig. 24], the locating pins 36, 40 are similar to those of [Fig. 19] and [Fig. 21], respectively. As second locating pins, they cooperate with the oblong locating orifices 21a and 31a.

[0087] As shown in the figures, the elongated portions 46 of the orifices 21a and 31a deform the locating pins 36, 40 over a region 47, 48 located at the bottom of said locating pins 36, 40.

[0088] The invention is not limited to the disclosed embodiments.List of reference numbers

[0089] 1Secondary optics unit 2Holder 3Cut-off shield 4Primary optics unit 5Printed circuit board 6Heat sink 7Longitudinal wall 8Front face 9Rear face 10Recesses 11Flange 12Fixation means 13Stacking pins 14Stacking holes 15, 15a, 15bLocating pins on the holder 16Lens 17Recess 18Coupling faces 19Annular boss 20Lateral face 21, 21a, 21bLocating orifices on the optics unit 22Pillar 23Excrescences 24Lower portion 25Upper portion 26Lateral side 27Direction joining two pillars 28Plane 29Depression 30, 30a, 30bLocating pins on the optics unit 31, 31a, 31bLocating orifices on the PCB 32Tips of the long stacking pins 33Printed circuit board 34, 35Locating orifice on the PCB 36Locating pin on the holder 37Continuous lateral thickness 38Primary optics unit 39Deformed region 40Locating pins on the optics unit 41Continuous lateral thickness 42Lower portion 43Upper portion 44Printed circuit board 45Deformed region 46Elongated portions of orifices 47, 48Deformed region

Claims

1. A module of at least two components of a vehicle headlamp, one of said components being an optical unit (4, 38) and the other component being selected in the list consisting of: - a light source holding part (5, 44), - a holder (2), wherein one (2, 4, 38) of the components has at least one locating pin (15, 30) comprising a pillar (22) having a plastically deformable outer lateral thickness (23, 37, 41) around the pillar (22), while another one (4, 38, 5, 44) of the components has a locating orifice (21, 31), and wherein said outer lateral thickness (23, 37,41) is configured to deform plastically and rest against the orifice (21, 31) when inserted into said orifice, thereby forming a firm abutment that keeps the pillar (22) centred inside the orifice (21, 31).

2. The module of claim 1, wherein at least one locating orifice (31) is located on the light source holding part (5, 44) and one corresponding locating pin (30, 40) is located on the optical unit (4, 38).

3. The module of claim 1 or claim 2, wherein at least one locating pin (15, 36) is located on the holder (15) and one corresponding locating orifice (21, 31) is located on the optical unit (4, 38).

4. The module of any one of claims 1-3, wherein the outer lateral thickness (23, 37, 3741) has a decreasing diameter from bottom to top along the pillar (22).

5. The module of claim 4, wherein the outer lateral thickness (37, 41) is divided into a lower portion (24, 42) that can be conical or prismatic and an upper portion (25, 43) that is conical.

6. The module of any one of claims 1-5, wherein the outer lateral thickness consists of excrescences (23). protruding from the pillar (22).

7. The module of claim 6, wherein, on a first single locating pin (15a, 30a), the excrescences (23) are arranged so as to achieve self-centring.

8. The module of claim 6 or claim 7, wherein, on a second locating pin (15b, 30b), the excrescences (23), preferably located symmetrically relative to a direction (27) joining the first and second locating pins, are arranged so as to achieve self-positioning perpendicularly to said direction.

9. The module of any one of claims 6-8, wherein the cross-section dimension of the pillar (22) is smaller than that of its corresponding locating orifice (21, 31) by at least 0.1 mm.

10. The module of any one of claims 1-5, wherein the outer lateral thickness consists of a continuous lateral thickness (37, 41) surrounding the pillar (22).

11. The module of any one of claims 1-10, further comprising a light source mounted on the light source holding part (5) and engaging with the optical unit (4) for forming a beam of light.

12. The module of any one of claims 1-11, wherein one of the locating pins is dimensioned such that it does not plastically deform in the locating aperture to enable CTE compensation.

13. A vehicle headlamp comprising an assembly of at least two components (2, 4, 5) positioned relative to each other in precise alignment according to any one of claims 1-12.

14. A vehicle equipped with a vehicle headlamp according to claim 13.

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