Assembly system for a vehicle headlight mask on a thermosetting material reflector

Abstract

The invention relates to a system for assembling a projector mask (40) made of thermoplastic material onto a reflector (30) made of thermosetting material, said system being characterized in that it comprises: - several elastically deformable clipping elements (43, 44, 45) arranged in the upper part of said mask, being spaced transversely apart from each other and provided to cooperate by snapping, during the assembly of said mask onto said reflector by a longitudinal translational movement, with respective complementary non-elastically deformable clipping elements (34, 35) provided along the upper edge of this reflector (30);as well as several vertical retaining elements arranged on said mask, each transversely at the level of a corresponding clipping element and below the latter, said vertical retaining elements being designed to cooperate by interlocking, during the assembly of said mask, with three respective complementary retaining elements provided on said reflector. Figure to be published with the abbreviation: Fig. 4;

Description

Title of the invention: System for assembling a headlight mask for a motor vehicle onto a thermosetting material reflector technical field

[0001] The present invention relates generally to the field of headlights for motor vehicles. It relates more particularly to a system for assembling a mask of such a headlight made of thermoplastic material onto a reflector made of thermosetting material. Previous technique

[0002] A motor vehicle includes, in a known manner, optical units mounted at the front of said vehicle and commonly referred to as headlights. These allow, on the one hand, the vehicle's surroundings to be illuminated to improve the driver's visibility, particularly at night, and, on the other hand, the vehicle's position to be signaled to other road users.

[0003] Such a projector classically comprises a hollow housing intended to be fixed to the structure of the vehicle, at least one light module housed fixedly in the housing and capable of providing one or more photometric functions of lighting or signaling, as well as an outer transparent cover glass fixed to the peripheral edge of the housing and covering the light module.

[0004] Each light module conventionally comprises at least one light source associated with a reflector capable of reflecting the light rays reaching it towards a space to be illuminated.

[0005] Some projectors also include a mask interposed between the reflector and the outer cover glass so that at least its front face is visible from outside the projector.

[0006] The function of such a mask is to form a transition between the reflector and the outer cover glass by concealing the edges of certain peripheral walls of this reflector while ensuring part of the style of the projector.

[0007] The mask is generally treated, for example by a metallization operation of its visible surface, to present an appearance similar to that of the edges of the reflector. It thus contributes significantly to defining the style of the light in question.

[0008] The mask and the reflector are generally each molded in one piece from a thermoplastic material such as Polycarbonate (PC), Polymethyl Methacrylate (PMMA) or Acrylonitrile Butadiene Styrene (ABS) and assembled to each other by screwing or clipping as disclosed for example in document FR 2 805 596 Al.

[0009] When the reflector has large dimensions, the geometric deformations of the part resulting from the demolding of the thermoplastic resin or caused by the heat of the light rays from the light source(s) are unfortunately significant enough to substantially impact the optical rendering of the photometric function(s) of the projector and lead to non-compliance with regulatory standards.

[0010] In order to avoid this problem, large reflectors are therefore generally made by molding from a thermosetting material.

[0011] Remaining completely geometrically inert, such a thermosetting material presents no risk of deformation during the injection process or afterwards in use.

[0012] Since thermosetting resin is particularly fluid during injection, the molds used cannot be as complex as those used for molding thermoplastic resins. The use of drawer molds is therefore prohibited to avoid seepage, which precludes the design of geometrically complex assembly interfaces.

[0013] The use of such a thermosetting material also does not allow the assembly of the reflector by screwing onto the mask due to a significant risk of stripping the fixing holes or of cracking / breaking the reflector during the screwing operations.

[0014] The implantation of clipping tabs on such a thermosetting material is also problematic because there is a high risk of breakage of these tabs during clipping operations. Description of the invention

[0015] The present invention aims to facilitate the assembly between a projector mask made of thermoplastic material and a reflector made of thermosetting material.

[0016] To this end, it proposes a system for assembling a motor vehicle headlight mask made of thermoplastic material onto a reflector made of thermosetting material, said system being characterized in that it comprises: - several elastically deformable clipping elements arranged in the upper part of said mask, spaced transversely apart from each other and designed to cooperate by snapping, during assembly of said mask onto said reflector by a longitudinal translational movement, with respective complementary non-elastically deformable clipping elements provided along the upper edge of this reflector; as well as - several vertical retaining elements arranged on said mask each transversely at the level of a corresponding clipping element and below the latter, said vertical retaining elements being provided to cooperate by interlocking, during the assembly of said mask on said reflector, with three respective complementary retaining elements provided on said reflector.

[0017] The invention thus makes it possible to carry out in a simple and economical manner the assembly without play or almost between such a thermoplastic mask and such a sand thermoset reflector.

[0018] No external support or fixing elements are required for this assembly. Furthermore, the absence of a deformable clip on the reflector eliminates any risk of cracking or breakage of the thermosetting material reflector.

[0019] According to preferred characteristics of said assembly system according to the invention: - it comprises three said clipping members associated with three said complementary clipping members and arranged longitudinally in a staggered manner opposite each other so as to constitute the three vertices of a first support triangle; - this one comprises three said vertical restraint devices associated with three said complementary restraint devices and arranged longitudinally in a staggered manner opposite each other so as to constitute the three vertices of a second support triangle extending substantially parallel to said first support triangle below the latter; - the said support triangle(s) point forwards; - at least one of said clipping elements consists of a tab designed to pass through, during the assembly of said mask on said reflector, an oblong hole provided on said reflector, said tab having a U-shaped cut-out delimiting an elastically deformable clipping tab provided with an inclined ramp extending to a retaining notch and designed to cooperate by snapping with said hole; - at least one of said clipping members consists of an elastically deformable tab having a light intended to cooperate by snapping, when assembling said mask on said reflector, with a tooth formed on said reflector and provided with an inclined ramp extending to a retaining tooth; - at least one of said vertical retaining devices consists of a flat rib extending substantially horizontally and designed to cooperate by interlocking, during the assembly of said mask on said reflector, with a corresponding slot of additional thickness provided on said reflector; - at least one of said vertical retaining devices consists of a hollow shaft extending longitudinally rearward from a wall of said mask and designed to cooperate by interlocking, during the assembly of said mask onto said reflector, with a corresponding hole of complementary shape and dimensions provided on a wall of said reflector; and / or - said system includes a lateral centering lug projecting longitudinally towards the rear from a wall of said mask and intended to cooperate in interlocking by shape correspondence, when assembling said mask onto said reflector, with a complementary recess provided in a wall of said reflector.

[0020] The invention also relates, in a second aspect, to a motor vehicle projector comprising a hollow housing having an opening closed by an outer transparent cover glass, a light module housed in said housing and equipped with a reflector made of thermosetting material, as well as a mask made of thermoplastic material interposed between said reflector and said outer cover glass; characterized in that said mask and said reflector are fixedly assembled to each other by such an assembly system. Brief description of the drawings

[0021] The description of the invention will now be continued by a detailed description of an exemplary embodiment, given below by way of illustration but not limitation, with reference to the accompanying drawings, on which: - [Fig.1] represents a front view of a motor vehicle projector comprising a reflector made of thermosetting material and a mask made of thermoplastic material attached to the latter by an assembly system according to the invention; - [Fig.2] is a three-quarter front perspective view of the projector reflector of [Fig.1], equipped with fixing elements involved in the assembly system according to the invention; - [Fig.3] represents a three-quarter rear perspective view of the projector mask of [Fig.1], equipped with fixing elements involved in the assembly system according to the invention; - [Fig.4] is a top view of the reflector / mask sub-assembly in assembled configuration; - [Fig.5], [Fig.6], [Fig.7] and [Fig.8] represent partial section views taken at the level of assembly areas along the vertical transverse planes identified respectively by V, VI, VII and VIII on [Fig.4]; - [Fig.9] is a rear view of the reflector / mask subassembly in its assembled configuration; and - [Fig. 10] and [Fig. 11] represent partial section views taken at the level of assembly areas along the vertical transverse planes identified respectively by X and XI on [Fig.9]. Description of the implementation methods

[0022] Fig. 1 represents a projector 1 of a motor vehicle intended to be mounted on the body structure of this vehicle by integrating with the contours of the adjacent body parts and those of the bumper.

[0023] An orthogonal coordinate system XYZ is defined in the figures, comprising three axes perpendicular to each other in pairs, namely: - an X-axis, defining a longitudinal direction, parallel to the longitudinal axis of the vehicle, - a Y-axis, defining a horizontal, transverse direction, which, together with the X-axis, defines a horizontal XY plane, and - a Z axis, defining a vertical direction, perpendicular to the horizontal XY plane.

[0024] In the description that follows, and by convention, the terms "front", "rear", "lower", and "upper" will be defined in relation to the mounting position of this projector 1 on such a motor vehicle.

[0025] Furthermore, the use of the term "substantially" indicates that a slight deviation is permitted from a predetermined nominal position or arrangement, while remaining within the scope of the invention. For example, "substantially vertical" indicates that a deviation of approximately 10° from a strictly vertical orientation is permitted within the scope of the invention.

[0026] As illustrated in [Fig.1], the projector 1 comprises a hollow housing 10 having an opening 10A and containing a light module capable of providing one or more photometric lighting functions (such as low beam and high beam functions) and / or signaling functions (such as lantern and flashing functions).

[0027] The projector 1 also includes an outer transparent cover glass 20, mounted in a sealed manner on the periphery of the opening 10A of the housing 10.

[0028] The light module comprises three light sources not visible on [Fig.1] and consisting, for example, of each one consisting of a high-power white LED mounted on a PCB (Printed Circuit Board) type printed circuit board mounted on a support.

[0029] These three light sources are associated with three respective reflective walls in the shape of a paraboloid 31 originating from the same reflector 30 shown alone in [Fig.2],

[0030] The front outer face (i.e., the one facing the outer cover glass 20) of each of these walls 31 is covered with a metallic coating reflective capable of redirecting light rays emitted by light sources towards a space to be illuminated.

[0031] The reflector 30 also includes three skirts 32 each extending longitudinally forward from a lateral edge and the lower edge of a respective reflective wall 31, these skirts 32 having striated or grained outer faces in order to break up the light rays reaching them so as to avoid the generation of parasitic reflected rays in undesired and potentially troublesome directions.

[0032] In order to exhibit excellent geometric stability despite its large dimensions and heating caused by the absorption of part of the energy of the light rays striking its reflective walls 31, this reflector 30 is made from a single piece of molding from a thermosetting polymer resin reinforced with natural and / or synthetic fibers (such as in particular BMC, an acronym for the English expression "Bulk Moulding Compound" and consisting of an unsaturated polyester resin loaded with glass fibers).

[0033] The projector 1 also includes a hollow mask 40 interposed between the reflector 30 and the outer cover glass 20 so that at least its front face is visible from outside the projector.

[0034] Represented alone on [Fig.3], the mask 40 forms a transition between the reflector 30 and the outer cover glass 20 by concealing in particular the upper edges of the three reflective walls 31 of this reflector 30.

[0035] Made from a single piece of molding from a thermoplastic material such as polycarbonate (PC), polymethyl methacrylate (PMMA) or acrylonitrile butadiene styrene (ABS), the mask 40 is rigidly fixed to the reflector 30 by means of an assembly system according to the invention.

[0036] This assembly system comprises three elastically deformable clipping members 43, 44, 45 extending from the rear edge of an upper wall of the mask 40, being transversely separated from each other (see [Fig.3]) and intended to cooperate by snapping, during the assembly of this mask 40 onto the reflector 30 by a front-to-back translational movement along the longitudinal demolding axis of this reflector 30, with three respective complementary non-elastically deformable clipping members 33, 34, 35 provided along the upper edge of this reflector 30 (see [Fig.2]).

[0037] Arranged at a first lateral end of the mask 40, the first clipping member 43 consists of a first tab intended to cooperate by snapping with an oblong hole 33 provided at the level of the corresponding lateral end of the upper edge of the reflector 30 (see figures 2 to 5).

[0038] Extending longitudinally towards the rear along a substantially horizontal average plane, this tab 43 has a U-shaped cut-out delimiting an elastically deformable clipping tab 431 oriented longitudinally and comprising a ramp 431A inclined upwards and forwards from the proximal rear end of this tab 431 to a retaining notch 43IB (see [Fig.5]).

[0039] During the assembly of the mask 40 onto the reflector 30, the rear end of the tab 43 passes through the oblong opening 33 until the inclined ramp 431A of its tab 431 comes to rest against the upper edge of this opening 33

[0040] The continuation of this translational movement causes the progressive lowering by pivoting of the tongue 431 as the upper edge of this light 33 slides along the inclined ramp 431 A.

[0041] As soon as this inclined ramp 431A has completely passed through the hole 33, the tongue 431 returns to its initial position, so that the notch 43 IB now facing the perimeter of the hole 33 prevents the removal of the tab 43 by a translational movement from back to front ([Fig.5]).

[0042] Approximately identical and arranged respectively at a second lateral end of the mask 40 and at a zone laterally distant from the two ends of this mask 40, the clipping members 44 and 45 consist of elastically deformable tabs provided to cooperate by snapping with two corresponding teeth 34, 35 provided respectively at the level of the corresponding lateral end of the upper edge of the reflector 30 and at the level of the separation zone between two reflective walls 31 (see figures 2 to 4, 6 and 7).

[0043] Extending longitudinally towards the rear along a substantially horizontal average plane, each leg 44, 45 has a rectangular opening 44A, 45A provided near its free rear end.

[0044] As illustrated by figures 6 and 7, each tooth 34, 35 comprises a ramp 34A, 35A inclined upwards and backwards from its front end to a retaining step 34B, 35B.

[0045] When assembling the mask 40 onto the reflector 30, the rear end of each of these tabs 44, 45 comes to rest against the ramp 34A, 35A of a corresponding tooth 34, 35.

[0046] The continuation of this translational movement along the assembly direction causes the progressive pivoting lifting of these tabs 44, 45 as their rear ends slide along the inclined ramps 34A, 35A, then the insertion of these ramps through the slots 44A, 45A which causes the tabs 44, 45 to return to their initial positions, the notches 34B, 35B, now opposite the rear edges of the slots 44A, 45A therefore prevent the tabs 44, 45 from being withdrawn by a back-to-forward translational movement (figures 6 and 7).

[0047] It will be noted with reference to [Fig.4] that the three tabs 43, 44, 45 of the mask 40 and the three complementary clipping members 33, 34, 35 provided on the reflector 30 are arranged longitudinally in a staggered manner opposite each other so as to constitute the three vertices of a first support triangle pointing forward and of which the central tab 44 and the clipping member 34 form the front point.

[0048] With reference to [Fig.3], the assembly system according to the invention also includes three vertical retaining members 46, 47, 48, each extending transversely at the level of a corresponding clipping tab 43, 44, 45, but below and in front of the latter.

[0049] These three vertical retaining members 46, 47, 48 are intended to cooperate by interlocking, during the assembly of this mask 40 on the reflector 30, with three respective complementary retaining members 36, 37, 38 provided in the upper part of this reflector 30 (see [Fig.2]).

[0050] Arranged respectively at the two lateral ends of the mask 40, the retaining members 46, 48 consist of two flat ribs extending substantially horizontally and intended to cooperate by interlocking with two corresponding slots of complementary thicknesses 36, 38 provided respectively at the two lateral ends of the reflector 30 (see figures 5 and 8).

[0051] Arranged transversely at the level of the clipping tab 44, the retaining member 47 is in this case constituted by a hollow cylindrical shaft extending longitudinally towards the rear from a substantially vertical wall of the mask 40 and intended to cooperate by fitting with a corresponding hole of complementary shape and dimensions 37 provided on a wall of the reflector 30 (see [Fig.6]).

[0052] It will be noted with reference to figures 2 and 3 that the three vertical retaining members 46, 47, 48 of the mask 40 and the three complementary retaining members 36, 37, 38 provided on the reflector 30 are arranged longitudinally in a staggered manner with respect to each other so as to constitute the three vertices of a second support triangle pointing forward and extending substantially parallel to the first support triangle below the latter, with the central member 47 and the complementary member 37 forming its front point.

[0053] The action of these two support triangles, offset vertically and longitudinally from each other, thus ensures excellent stability of the mask 40 on the reflector 30 after its assembly, without risk of pivoting of one relative to the other.

[0054] It will also be noted with reference to [Fig. 11] that the interlocking cooperation by matching form between the hollow cylindrical barrel 47 and the bore 37 also makes it possible to ensure the lateral centering of the mask 40 vis-à-vis the reflector 30.

[0055] As illustrated by [Fig. 10] and in order to ensure even more precise lateral centering, the assembly system according to the invention also advantageously comprises a lug 49 (also visible on [Fig. 3]) projecting longitudinally towards the rear from a wall of the mask 40 near the tab 45 and provided to cooperate by matching form, when assembling this mask 40 on the reflector 30, with a complementary recess 39 (also visible on [Fig. 2]) provided in a wall of the reflector 30 near the tooth 35.

[0056] According to alternative embodiments not shown, the number and / or shape of the vertical clipping and / or retaining elements provided on the mask may differ. The same applies to the number and / or shape of the additional clipping and / or retaining elements.

[0057] According to other embodiments not shown, the mask and the reflector may be devoid of specific centering means such as the lug 49 and the recess 39.

[0058] Finally, it should be noted that the present invention is not limited to the embodiments described and represented, but also encompasses all variants of execution within the reach of a person skilled in the art.

Claims

Demands

1. Assembly system for a motor vehicle headlight mask (40) made of thermoplastic material on a reflector (30) made of thermosetting material, said system being characterized in that it comprises: - several elastically deformable clipping members (43, 44, 45) arranged in the upper part of said mask (40) being transversely separated from each other and provided to cooperate by snapping, during the assembly of said mask (40) on said reflector (30) by a longitudinal translational movement, with respective complementary non-elastically deformable clipping members (33, 34, 35) provided along the upper edge of this reflector (30);as well as - several vertical retaining elements (46, 47, 48) arranged on said mask (40), each transversely at the level of a corresponding clipping element (43, 44, 45) and below the latter, said vertical retaining elements (46, 47, 48) being provided to cooperate by interlocking, during the assembly of said mask (40) on said reflector (30), with three respective complementary retaining elements (36, 37, 38) provided on said reflector (30), characterized in that the assembly system comprises three said clipping elements (43, 44, 45) associated with three said complementary clipping elements (33, 34, 35) and arranged longitudinally in a stepped manner opposite each other so as to constitute the three vertices of a first support triangle.;

2. Assembly system according to claim 1, characterized in that it comprises three said vertical retaining members (46, 47, 48) associated with three said complementary retaining members (36, 37, 38) and arranged longitudinally in a stepped manner opposite each other so as to constitute the three vertices of a second support triangle extending substantially parallel to said first support triangle below the latter.

3. Assembly system according to any one of claims 1 or 2, characterized in that said support triangle(s) point forward.

4. Assembly system according to any one of claims 1 to 3, characterized in that at least one of said clipping members (43, 44, 45) is constituted by a tab (43) provided to pass through, during the assembly of said mask (40) on said reflector (30), an oblong hole (33) provided on said reflector (30), said tab (43) having a U-shaped cut-out delimiting an elastically deformable clipping tab (431) provided with an inclined ramp (431 A) extending to a retaining notch (43 IB) and provided to cooperate by snap-locking with said hole (33).

5. Assembly system according to any one of claims 1 to 4, characterized in that at least one of said clipping members (43, 44, 45) is constituted by an elastically deformable tab (44, 45) having a slot (44A, 45A) intended to cooperate by snapping, during the assembly of said mask (40) on said reflector (30), with a tooth (34, 35) formed on said reflector (30) and provided with an inclined ramp (34A, 35A) extending to a retaining tooth (34B, 35B).

6. Assembly system according to any one of claims 1 to 5, characterized in that at least one of said vertical retaining members (46, 47, 48) is constituted by a flat rib (46, 48) extending substantially horizontally and provided to cooperate by interlocking, during the assembly of said mask (40) on said reflector (30), with a corresponding slot of complementary thickness (36, 38) provided on said reflector (30).

7. Assembly system according to any one of claims 1 to 6, characterized in that at least one of said vertical retaining members (46, 47, 48) is constituted by a hollow barrel (47) extending longitudinally towards the rear from a wall of said mask (40) and provided to cooperate by interlocking, during the assembly of said mask (40) on said reflector (30), with a corresponding hole of complementary shape and dimensions (37) provided on a wall of said reflector (30).

8. Assembly system according to any one of claims 1 to 7, characterized in that it comprises a lateral centering lug (49) projecting longitudinally towards the rear from a wall of said mask (40) and provided to cooperate in interlocking by shape matching, during the assembly of said mask (40) on said reflector (30), with an additional recess (39) provided in a wall of said reflector (30).

9. Motor vehicle projector (1) comprising a hollow housing (10) having an opening (10A) closed by an outer transparent cover glass (20), a light module housed in said housing (10) and having a reflector made of thermosetting material (30), and a mask made of thermoplastic material (40) interposed between said reflector (30) and said outer cover glass (20); characterized in that said mask (40) and said reflector (30) are fixedly assembled to each other by an assembly system according to any one of claims 1 to 8.