Light module, manufacturing process for a light module, and rear-vision device

Abstract

LIGHT MODULE, METHOD FOR MANUFACTURING A LIGHT MODULE AND REARVIEW DEVICE The present invention relates to a light module (10) comprising a lens unit (40) which is formed with a base (42), a cover (44) and one or more side walls between the base (42) and the cover (44), in which the side wall(s) provide one or more insertion openings (49); a printed circuit board unit (30) which supports one or more light sources and is inserted into the lens unit (40) through a first insertion opening (49) of the insertion opening(s) (49) such that the light emitted by the light source(s) exits the light module (10) through the base (42) and / or the cover (44) of the lens unit (40);and a housing unit (50) having a bottom opening (52), a cover opening (54), and one or more side walls between the bottom opening (52) and the cover opening (44), wherein the lens unit (40) is arranged inside the housing unit (40) such that the bottom opening (52) of the housing unit (50) is closed by the bottom (42) of the lens unit (40), the cover opening (54) of the housing unit (50) is closed by the cover (44) of the lens unit (40), and the insertion opening(s) (49) of the lens unit (40) are closed by the side wall(s) of the housing unit (50). It also relates to an external rear-vision device with such a light module (10). Figure for the abbreviation: Figure 3;

Description

Title of the invention: Light module, method of manufacturing a light module and rearview device

[0001] The present invention relates to a light module, in particular designed for an exterior rearview device, and an exterior rearview device for a vehicle equipped with such a light module.

[0002] Document US 2005 / 0168922 A1 relates to a light module in the form of an optoelectronic component based on surface mount technology, said component comprising an electrically conductive material, an opaque plastic material and a cavity, wherein the electrically conductive material serves as a base for the assembly, the opaque plastic material provides a housing for the entire component and the cavity is positioned inside the plastic material in which an optoelectronic chip is fixed. The known light module provides a solderless LED carrier without additional measures for attachment to a device.

[0003] Document EP 3 138 734 B1 relates to a light assembly for an exterior rearview device comprising at least one light module for the light assembly and at least one printed circuit board unit, with the light module comprising a light source unit with at least one cable for electrical connection with said printed circuit board unit of the light assembly, with the light source unit comprising a radiation surface and a light source housing, a housing unit supporting the light source unit and being provided with connection and / or holding means for attachment to at least one part, in particular a housing part, of the rearview device, and closing means for waterproofing and dustproofing the connection between the light module and the at least one part.The printed circuit board unit is positioned away from the light module and the light module cable(s) is / are solder bonded to the printed circuit board unit providing a solder pad pattern. The closure means forms the perimeter of the housing unit in the region supporting the light source unit and the housing unit is formed together with the light source housing and the closure means by 2-K injection molding.

[0004] The objective of the present invention is to provide a light assembly which is not only compact and easy to fix but also easy to manufacture and at least weather resistant, preferably waterproof.

[0005] This objective is achieved by means of a light module, comprising a lens unit which is formed with a bottom, a cover and one or more side walls. provided between the bottom and the cover, the side wall(s) providing one or more insertion openings; a printed circuit board unit which supports one or more light sources and is inserted into the lens unit through a first insertion opening of the insertion opening(s) such that light emitted by the light source(s) exits the light module through the bottom and / or the cover of the lens unit;and a housing unit which is provided with a bottom opening, a cover opening and one or more side walls between the bottom opening and the cover opening, the lens unit being arranged inside the housing unit such that the bottom opening of the housing unit is closed by the bottom of the lens unit, the cover opening of the housing unit is closed by the cover of the lens unit and the one or more insertion openings of the lens unit are closed by the one or more side walls of the housing unit. ;

[0006] It is proposed that the printed circuit board unit is supported by the lens unit, wherein preferably two opposite edges of the printed circuit board unit are arranged on or in two guide rails provided by the lens unit, in particular by two opposite side walls of the lens unit.

[0007] Embodiments may further be provided in which the printed circuit board unit provides one or more connection pins and / or at least one extension, wherein preferably the one or more connection pins extend into a second insertion opening of the one or more insertion openings of the lens unit and / or the at least one extension extends into a third insertion opening of the one or more insertion openings of the lens unit, with in particular the second and / or third insertion opening(s) provided by the first insertion opening.

[0008] Furthermore, embodiments may be characterized in that the housing unit is provided with at least one stop and / or alignment feature for the lens unit and / or the printed circuit board unit, wherein preferably the housing unit provides a first step-like extension around its bottom opening for positioning the bottom of the lens unit and / or a second step-like extension around its cover opening for positioning the cover of the lens unit and / or an internal step on the internal surface of the side wall closing the first insertion opening of the lens unit for positioning the at least one extension of the printed circuit board unit.

[0009] With the present disclosure, it is also proposed that a first solder strip is provided between the housing unit and the lens unit, preferably around the bottom opening of the housing unit, in particular defined by a tip extending parallel to the first step-like extension and / or that a second solder strip weld is provided between the housing unit and the lens unit, preferably around the cover opening of the housing unit, particularly defined by a tip extending along the second step-like extension.

[0010] The first and second welding strips can be produced simultaneously.

[0011] It is proposed that at least one connector extension is provided by the housing unit for inserting a connector for connecting the printed circuit board unit, wherein preferably the at least one connector extension is provided by the side wall closing the at least one insertion opening of the lens unit, in particular formed on the outer surface of the side wall in the region of the inner step and / or wherein an insulating rack preferably extends in the at least one connector extension, in particular between two connection pins of the at least one connection pin of the printed circuit board unit.

[0012] Additionally, the light source(s) may comprise at least two, preferably three, light source units, wherein preferably each light source unit comprises an LED unit.

[0013] The lens unit may be formed of a clear and / or transparent plastic material, and / or the housing unit may be formed of an opaque and / or non-transparent plastic material.

[0014] It is further proposed that the housing unit is provided, in particular formed, with a fastening portion, wherein preferably the fastening portion is designed to fasten the light unit to a rear-view device via a clip-on, snap-in and / or latch connection and / or wherein preferably the fastening portion is provided with a fastening extension and / or wherein preferably the fastening portion has a T-shaped cross-section.

[0015] The present invention also relates to an external rear vision device with at least one rear vision element arranged in a head assembly and at least one light unit of the present invention for providing a turn signal indicator, blind spot detection, a logo lamp, a door handle light and / or an approach light.

[0016] It is also proposed that the radiating surface of the light module, preferably provided by the bottom of the lens unit, aligns with an outer surface of the external rearview device.

[0017] Embodiments of the external rearview device of the present invention may further comprise a base assembly for attachment to a vehicle, the head assembly being movable relative to the base assembly.

[0018] It is also proposed that at least one first light module is attached to the head assembly, in particular to a head frame and / or that at least one second light module is attached to the base assembly, wherein preferably the attachment part of the light module provides a clip-on, quick-release and / or releasable latch connection.

[0019] Finally, it is proposed to insert a connector into each connector extension of the light module to close it watertight.

[0020] The foregoing summary, together with the following detailed description, will be better understood when viewed in conjunction with the accompanying drawings. For purposes of illustration, certain examples of the present invention are illustrated in the drawings. It will be understood, however, that the present description is not limited to the precise arrangements and elements illustrated. The accompanying drawings incorporated in and forming a part of this application illustrate one embodiment of the system, apparatus, and methods of the present disclosure and, in conjunction with the detailed description, serve to explain the advantages and principles of the present disclosure, wherein:

[0021] [Fig. 1a] illustrates a perspective view of a lens unit of a light module of the present invention;

[0022] [Fig.lb] illustrates another perspective view of the lens unit of [Fig.la];

[0023] [Fig.2] illustrates an elevational view taken on a housing unit of the module light of the present invention;

[0024] [Fig.3] illustrates a longitudinal cross-section of the light module of the present invention;

[0025] [Fig.4] illustrates a perspective view of the light module of [Fig.3], with a connector;

[0026] [Fig.5] illustrates a perspective view of the light module of [Fig.4], attached to a head frame of a rear-view device;

[0027] [Fig.6a] illustrates a cross-section of the casing unit of [Fig.2];

[0028] [Fig.6b] illustrates a cross-section taken along line BB of [Fig.6a];

[0029] [Fig.6c] illustrates an enlarged detailed view of the lower end of [Fig.6b]; and

[0030] [Fig.6d] illustrates an enlarged view of the upper end of [Fig.6b].

[0031] A light module 10 of the present invention is illustrated in [Fig. 3] as well as in [Fig. 4]. The light module 10 thus comprises a housing unit 50 made of non-transparent plastic illustrated in [Fig. 2] and a lens unit 40 made from a crystalline material, in particular plastic, housing a printed circuit board unit 30 supporting three LED units 20, 21, 22, as shown in Figures 1a and 1b. [Fig. 3] thus illustrates the lens unit 40 of Figures 1a and 1b arranged inside the housing unit 50 of [Fig. 2].

[0032] The lens unit 40 comprises a bottom 42 serving as a light window for the light emitted by one or two LED units 20, 21, 22. Opposite said bottom 42 there is a cover 44, between the bottom 42 and the cover 44 there is at least one side wall and below the cover 44 the printed circuit board unit 30 with the LED units 20, 21, 22 is inserted through the opposite edges of the printed circuit board unit 30 into two guide rails 46, 48 provided by the lens unit 40. To enable insertion of the printed circuit board unit 30 with the LED units 20, 21, 22 into the lens unit 40, the lens unit 40 is provided with at least one insertion opening 49 provided between its bottom 42 and the cover 44 and thus provided with the at least one side wall, as best shown in [Fig. 3]. For example, the lens unit 40 may be formed with 5 three side walls between the bottom 42 and the cover 44.

[0033] The housing unit 50 is formed with a connector extension 51 which will be explained below. In addition, said housing unit 50 is formed with a bottom opening 52, a cover opening 54 and at least one interposed side wall. These two openings 52, 54 are closed as soon as the lens unit 40 is inserted into the housing unit 50. In detail, the bottom 42 of the lens unit 40 closes the bottom opening 52 of the housing unit 50, while the cover 44 of the lens unit 40 closes the cover opening 54 of the housing unit 50 as shown in [Fig. 3]. In addition, the insertion opening 49 of the lens unit 40 is closed by the housing unit 50, for example by the side wall of the housing unit 50 provided with the connector extension 51.

[0034] In order to obtain a sealed light module 10, the lens unit 40 and the housing unit 50 are connected to each other by two separate solder strips, as shown in [Fig. 2] by the two solder strips 56, 58 and in [Fig. 3] at the solder regions 56a, 56b, 58a and 58b. No additional O-rings are therefore necessary.

[0035] In addition, a sealed connector 100 may be inserted into the connector extension 51 as shown in [Fig. 4] when the light module 10 is attached to a rearview device, in particular to a head frame 200 thereof, as shown in [Fig. 5]. The connector 100 serves not only to establish an electrical connection between two connection pins 32, 34 extending out of the printed circuit board unit 30 and thus from the printed circuit board unit 30 with a control unit and / or a power supply source (not shown), via the cables 110, 120, but also to provide the final seal sealing the light module 10 such that all openings in the housing are closed. In fact, the connector 100 closes both the opening of the housing unit 50 in the region of the connector extension 51 as well as the insertion opening 49 in the region of the two connection pins 32, 34.

[0036] In addition to the two connection pins 32, 34, the printed circuit board unit 30 is provided with a fixing extension 36, see Figures 1a, 1b and 3. Said fixing extension 36 as well as the two connection pins 32, 34 extend in the direction of the insertion opening 49 and the fixing extension 36 nests an internal step 59 of the housing unit 50 extending into the interior of the housing unit 50. The fixing extension 36 and the step 59 therefore ensure the correct location of the lens unit subassembly 40 together with the printed circuit board unit 30 supporting the LED units 20, 21, 22 in the housing unit 50.

[0037] The housing 50 is also provided with a fixing portion 60, most easily visible in Figures 4 and 5. The fixing portion is provided with a fixing extension 61 such that its cross-section takes on a substantially T-shape. The fixing portion 60 is adapted for a clip-on connection of the light module 10 to the head frame 200.

[0038] The details of the tight closure provided by the two separate weld strips 56, 58 with the weld region 56a, 56b, 58a, 58b are illustrated in more detail with respect to Figures 6a to 6d.

[0039] [Fig.6a] illustrates a cross-section of the housing unit 50 and [Fig.6b] illustrates the cross-section taken along the line BB of [Fig.6a] which passes through the two weld strips 54, 58. Details of the bottom weld strip region 56b are illustrated in [Fig.6d] and details of the top weld strip region 56b are illustrated in [Fig.6c].

[0040] Accordingly, the edges provided around the openings 52 and 54 of the housing unit 50 are formed to support the bottom 42 and the cover 44 of the lens unit 40, respectively, and to facilitate welding to seal the unit 10. The step-like extensions 56ba and 58ba are provided in this regard to encompass an edge of the bottom 42 and the cover 44, respectively. In addition, the tips 56bb and 58bb serving as welding strips 56, 58 extending parallel to either the step-like extension 56ba or the respective step-like extension 58ba are visible in FIGS. 6d and 6c.

[0041] The final light unit 10, once attached to the rearview device and connected to the connector 100 inserted in the connector extension 51, is a sealed module with the lens 40 allowing the light from the LED to pass through the bottom of the lens 42 and the bottom opening 54 of the housing unit 50 according to the EC 48 standard.

[0042] Those skilled in the art will see that changes may be made to the embodiments described above without departing from the broad inventive concept of the invention. It will therefore be understood that the disclosed invention is not limited to the particular embodiments disclosed but is intended to cover modifications within the spirit and scope of the present invention. List of reference signs 10 light module 20 LED units 21 LED units 22 LED units 30 pcb unit 32 pin connection 34 connection pin 36 extension 40 lens unit 42 background 44 cover 46 guide rail 48 guide rail 49 insertion opening 50 crankcase unit 51 connector extension 52 bottom opening 54 lid opening 56 welding strip 56a, 56b weld region 56ba step type extension 56bb tip 58 welding strip 58a, 58b weld region 58ba step type extension 58bb tip 59 internal step 60 fixing element 61 attachment extension 100 connector 110 cable 110 cable 200 head frame

Claims

Claims

1. Light module (10), comprising: - a lens unit (40) which is formed with a bottom (42), a cover (44) and one or more side walls provided between the bottom (42) and the cover (44), the one or more side walls providing one or more insertion openings (49); - a printed circuit board unit (30) which supports one or more light sources and is inserted into the lens unit (40) through a first insertion opening (49) of the one or more insertion openings (49) such that the light emitted by the one or more light sources exits the light module (1) through the bottom (42) and / or the cover (44) of the lens unit (40);and - a housing unit (50) which is provided with a bottom opening (52), a cover opening (54) and one or more side walls between the bottom opening (52) and the cover opening (44), the lens unit (40) being arranged inside the housing unit (40) in such a way that the bottom opening (52) of the housing unit (50) is closed by the bottom (42) of the lens unit (40), the cover opening (54) of the housing unit (50) is closed by the cover (44) of the lens unit (40) and the one or more insertion openings (49) of the lens unit (40) are closed by the one or more side walls of the housing unit (50).;

2. Light module according to claim 1, wherein the printed circuit board unit (30) is supported by the lens unit (40), wherein preferably two opposite edges of the printed circuit board unit (30) are arranged on or in two guide rails (46, 48) provided by the lens unit (40), in particular by two opposite side walls of the lens unit (40).

3. A light module according to claim 1 or 2, wherein the printed circuit board unit (30) provides one or more connection pins (32, 34) and / or at least one extension (36), wherein preferably the one or more connection pins (32, 34) extend into a second insertion opening (49) of the one or more insertion openings (49) of the lens unit (40) and / or the at least one extension (36) extends into a third insertion opening (49) of the one or more insertion openings (49) of the lens unit (40), with in particular the second and / or third insertion opening (49) provided by the first insertion opening (49).

4. A light module according to any preceding claim, wherein the housing unit (50) is provided with at least one stop and / or alignment feature for the lens unit (40) and / or the printed circuit board unit (30), wherein preferably the housing unit (50) provides a first step-like extension (56ba) around its bottom opening (52) for positioning the bottom (42) of the lens unit (40) and / or a second step-like extension (58ba) around its cover opening (54) for positioning the cover (44) of the lens unit (40) and / or an internal step (59) on the internal surface of the side wall closing the first insertion opening (49) of the lens unit (40) for positioning the at least one extension (36) of the printed circuit board unit (30).

5. A light module according to any preceding claim, wherein a first solder strip (56) is provided between the housing unit (50) and the lens unit (40), preferably around the bottom opening (52) of the housing unit (50), in particular defined by a tip (56bb) extending parallel to the first step-like extension (56ba), and / or a second solder strip (58) is provided between the housing unit (50) and the lens unit (40), preferably around the cover opening (54) of the housing unit (50), in particular defined by a tip (58bb) extending along the second step-like extension (56ba).

6. A light module according to any one of the preceding claims, wherein at least one connector extension (51) is provided by the housing unit (50) for inserting a connector for connecting the printed circuit board unit (30), wherein preferably the at least one connector extension (51) is provided by the side wall closing the at least one insertion opening (49) of the lens unit (40), in particular formed on the outer surface of the side wall in the region of the inner step (59); and / or wherein preferably an insulating rack (53) extends into the at least one a connector extension (51), in particular between two connection pins (32, 34) of the connection pin(s) of the printed circuit board unit (30).

7. A light module according to any preceding claim, wherein the light source(s) comprise at least two, preferably three, light source units, wherein preferably each light source unit comprises an LED unit (20, 21, 22).

8. A light module according to any preceding claim, wherein the lens unit (40) is formed from a clear and / or transparent plastic material and / or the housing unit (50) is formed from an opaque and / or non-transparent plastic material.

9. Light module according to any one of the preceding claims, wherein the housing unit (50) is provided, in particular formed, with a fastening portion (60), wherein preferably the fastening portion (60) is designed to fasten the light module (10) to a rear-view device via a clip-on, snap-in and / or lock connection, and / or wherein preferably the fastening portion (60) is provided with a fastening extension (61), and / or wherein preferably the fastening portion (60) has a T-shaped cross-section.

10. External rearview device with at least one rearview element arranged in a head assembly and at least one light module (10) according to any one of the preceding claims for providing a turn signal indicator, blind spot detection, a logo lamp, a door handle light and / or an approach light.

11. An external rearview device according to claim 10, wherein the radiating surface of the light module (10), preferably provided by the bottom (42) of the lens unit (40), aligns with an outer surface of the external rearview device.

12. An external rearview device according to claim 10 or 11, further comprising a base assembly for attachment to a vehicle, wherein the head assembly is movable relative to the base assembly.

13. An external rear view device according to any one of claims 10 to 12, wherein at least one first light module (10) is attached to the head assembly, in particular to a head frame (200), and / or at least one second light module (10) is attached to the base assembly, wherein preferably the attachment portion (60) of the light module (10) provides a clip-on, snap-in and / or releasable latch connection.

14. An external rearview device according to any one of claims 10 to 13, wherein a connector (100) is brought into each connector extension (51) of the light module (10) to seal it.

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