Assembling method of light module for automobile headlamp

Abstract

To provide an improved assembling method of a light module for an automobile headlamp.SOLUTION: An assembling method includes the following steps. a) A primary optical system 100 including a lens portion 110 corresponding to a light source 300 and a fixing device 150, a base body 200 for holding the light source 300 and the primary optical system 100, and the light source 300 arranged at the base body 200 are included. b) An adhesive 400 is applied to a fixing hole 210 of the base body 200. c) The primary optical system 100 is aligned to a final position of the base body 200 so that light radiated by the light source 300 can be received by the lens portion 110 of the primary optical system 100, however, a salient part 160 of the primary optical system 100 is inserted into the fixing hole 210 at the final position. d) The adhesive 400 is hardened by radiating hardening light to a light incident face 170 of the fixing device 150, however, since the fixing device 150 hardens the adhesive 400, the hardening light is introduced to a light emission portion 161 of the salient part 160 in the primary optical system 100.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] This application claims the benefit of Paris Convention priority from European Patent Application No. 23191990.3, filed on August 17, 2023, the entire contents of which are incorporated herein by reference.

[0002] The present invention relates to a method for assembling a light module for a motor vehicle headlamp. [Background technology]

[0003] As headlamps and headlamp light modules decrease in size (are miniaturized), it is necessary to find means and methods for mounting components, especially the primary optics, that are usable in this small size. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] WO 2021 / 213642 A1 [Patent Document 2] FR 3 085 903 A1 [Patent Document 3] WO 2020 / 025419 A1 [Patent Document 4] DE 10 2018 128863 A1 [Patent Document 5] EP 2 693 108 A1 [Patent Document 6] DE 10 2008 033416 A1 Summary of the Invention [Problem to be solved by the invention]

[0005] Due to the small size, it becomes increasingly difficult to ensure uniform curing of the adhesive, which creates stresses at the adhesive points and, consequently, distortion of the position of the primary optics.

[0006] SUMMARY OF THE PRESENT EMBODIMENT It is therefore an object of the present invention to provide an improved method for assembling a light module for an automobile headlamp to overcome the drawbacks of the prior art. [Means for solving the problem]

[0007] According to one aspect of the present invention, A method for assembling a light module for an automotive headlamp is provided. The method comprises the following steps, performed in the order listed: a) A primary optical system including a lens portion corresponding to a light source and a fixing device, wherein the fixing device includes at least one protrusion and a light entrance surface for receiving curing light, and the at least one protrusion includes a light exit portion for emitting the curing light; a base configured to hold at least one light source and the primary optical system, the base including at least one fastening hole configured to receive at least one protrusion of the primary optical system; At least one light source disposed on the substrate To provide; b) applying adhesive to at least one fastening hole in said substrate; c) positioning the primary optical system to a final position on the base such that light emitted by the at least one light source can be received by a lens portion of the primary optical system, where in the final position at least one protrusion of the primary optical system is inserted into at least one fixing hole of the base; d) curing the adhesive by emitting curing light to a light input surface of the fixing device, the fixing device being configured to direct the curing light to a light output portion of a protrusion within the primary optical system to cure the adhesive. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] (Mode 1) See one aspect of the present invention above. (Mode 2) In the method according to mode 1, In step a), it is preferable that a robot arm for holding the primary optical system is further provided, wherein the fixing device includes at least one holding element configured to correspond to the robot arm such that the robot arm can engage with the at least one holding element to hold the primary optical system, and in step c), the robot arm holds the primary optical system via the holding element and aligns the primary optical system. (Mode 3) In the method according to mode 1 or 2, especially mode 1, The curing light is preferably UV light. (Mode 4) In the method according to mode 3, The UV light is preferably generated by a spot-type UV light source. (Mode 5) In the method according to any one of Modes 1 to 4, especially Mode 1, The adhesive is preferably a UV (curable) adhesive. (Mode 6) In the method according to any one of Modes 1 to 5, especially Mode 1, Preferably, the adhesive is a hybrid adhesive. (Mode 7) In the method according to any one of Modes 2 to 6, particularly Mode 2, The robotic arm preferably includes a UV light source. (Mode 8) In the method according to any one of Modes 2 to 7, particularly Mode 2, Preferably, said robot arm comprises a UV glue device for applying UV glue to the at least one fixing hole in step b). (Mode 9) In the method according to any one of Modes 2 to 8, particularly Mode 2, The primary optical system preferably includes at least two holding elements arranged (respectively) on opposite sides (across the lens portion) of the primary optical system. (Mode 10) In the method according to any one of Modes 2 to 9, particularly Mode 2, The at least one retaining element is preferably configured as a protrusion. (Mode 11) In the method according to any one of Modes 2 to 10, particularly Mode 2, It is preferable that the at least one holding element and / or the protrusion functions as a light guide for the curing light to guide the curing light from the light entrance surface to the light exit portion and from the light exit portion to the outside. (Mode 12) In the method according to any one of Modes 1 to 11, especially Mode 1, The at least one light source is preferably configured as an LED. (Mode 13) In the method according to any one of Modes 1 to 12, especially Mode 1, In a further step e), when the primary optic is in its final position on the substrate, additional adhesive is preferably applied into the fixing holes in order to further strengthen the fixing of the primary optic in its final position.

[0009] To achieve the above object, the method comprises the following steps a) to d) performed in the order listed: a) A primary optical system including a lens portion corresponding to a light source and a fixing device, where the fixing device includes at least one protrusion and a light entrance surface for receiving curing light, and the at least one protrusion includes a light exit portion for emitting the curing light; a base configured to hold at least one light source and a primary optical system, the base including at least one fastening hole configured to receive at least one protrusion of the primary optical system; At least one light source disposed on the substrate To provide; b) applying (applying or spreading) adhesive into at least one fastening hole in the substrate; c) positioning the primary optical system to a final position on the substrate such that light emitted by the at least one light source can be received by a lens portion of the primary optical system, where in the final position at least one protrusion of the primary optical system is inserted into at least one fixing hole of the substrate; d) curing the adhesive by radiating curing light onto a light incidence surface of the fixing device, the fixing device being configured to direct (guide) the curing light within the primary optical system to a light exit portion of the protrusion in order to cure the adhesive.

[0010] This ensures uniform curing of the adhesive and no distortion of the primary optic in its final position.

[0011] Advantageously, in the final position of the primary optics on the substrate, the light-exiting portion of the protrusion of the primary optics is positioned such that the adhesive directly covers the light-exiting portion, in other words, the adhesive is disposed between the substrate and the light-exiting portion.

[0012] Advantageously, in step a), a robot arm for holding the primary optical system is further provided, and the fixing device includes at least one holding element configured to correspond to the robot arm so that the robot arm can engage (mate) with the at least one holding element to hold the primary optical system, and in step c), the robot arm holds the primary optical system via the holding element and aligns the primary optical system.

[0013] Advantageously, the curing light is UV light.

[0014] Advantageously, the UV light is generated by a spot-type UV light source. Additional beam shaping optics can couple the UV light with pinpoint precision through the light entrance surface into the holding element. Advantageously, the adhesive is a UV (curable) adhesive.

[0015] Advantageously, the adhesive is a hybrid adhesive. So-called hybrid adhesives are used for bonding in positions where UV light cannot reach directly due to the specific geometry. The thermal curing of these hybrid adhesives increases the load on the optical material. Complex devices are additionally required to precisely maintain the final position during this very long thermal curing process.

[0016] Advantageously, the robotic arm includes a UV light source.

[0017] Advantageously, the robot arm comprises a UV glue (application) device for applying the UV glue in step b) to the at least one fixing hole.

[0018] Advantageously, the primary optical system comprises at least two holding elements arranged (respectively) on opposite (both sides) of the primary optical system (across the lens portion).

[0019] Advantageously, at least one holding element is configured as a protrusion.

[0020] Advantageously, at least one holding element and / or protrusion functions as a light guide for the curing light to guide the curing light from the light entrance surface to the light exit portion and from the light exit portion to the outside.

[0021] Advantageously, the at least one light source is configured as an LED.

[0022] Advantageously, in a further step e), when the primary optical system is in its final position on the base, additional adhesive is dispensed (applied or coated) into the fixing holes in order to further strengthen the fixation of the primary optical system in its final position.

[0023] It should be noted here that, unless stated otherwise, the descriptions and features referring to the method according to the invention also apply to the apparatus according to the invention and vice versa.

[0024] The invention is explained in more detail below with the aid of exemplary drawings. [Brief description of the drawings]

[0025] [Figure 1] 1 is a cross-sectional view of an example of a light module assembled by one method according to the present invention, the light module including primary optics aligned with a light source on a substrate. [Diagram 2] FIG. 13 is a perspective view of an example of a robotic arm engaging with a primary optic to align the primary optic to a substrate. [Diagram 3] 3 is a cross-sectional view of the assembly step of FIG. 2 along line AA. EXAMPLES

[0026] 1 shows an example of a light module 10 for a vehicle headlamp assembled by a method according to the present invention. The method includes a first step a) in which a primary optical system 100 is provided. The primary optical system 100 includes a lens portion 110 corresponding to a light source 300 and a fixing device 150, the fixing device 150 including at least one protrusion 160 and a light entrance surface 170 for receiving the curing light, and the at least one protrusion 160 includes a light exit portion 161 for exiting the curing light. In the illustrated example, the curing light is UV light.

[0027] Further provided is a base 200 configured to hold at least one light source 300 and the primary optical system 100. The base 200 includes two fixing holes (fixing openings) 210 configured to receive at least one protrusion 160 of the primary optical system 100. Further provided is a light source 300 disposed on the base 200. In the illustrated example, the light source 300 is configured as an LED.

[0028] Further, a robot arm 500 (which can be seen in Figs. 2 and 3) is provided for holding the primary optical system 100. The fixing device 150 includes two holding elements 180 configured to correspond to the robot arm 500 such that the robot arm 500 can engage with the holding elements 180 to hold the primary optical system 100. As can be seen in Figs. 1-3, the holding elements 180 are configured as protrusions 160 and are (respectively) arranged on opposite (both sides) of the primary optical system 100 (in the cross section shown) (across the lens portion 110).

[0029] In a next step b), adhesive 400 is applied (applied or spread or added) into (in) the two fixing holes 210 of the substrate 200. In the illustrated example, the adhesive is a UV adhesive or a hybrid adhesive. Furthermore, the robot arm 500 includes a UV adhesive (applying or applying) device (not shown) for applying the UV adhesive into (in) the fixing holes 210.

[0030] In a further step c), the primary optical system 100 is brought (applied) to a final position on the substrate 200, whereby the robot arm 500 holds (continues to hold) the primary optical system 100 via the holding element 180 and aligns the primary optical system 100 such that the light emitted by the light source 300 can be correctly received by the lens portion 110 of the primary optical system 100. In the final position, at least one protrusion 160 of the primary optical system 100 is inserted into a fixing hole 210 of the substrate 200.

[0031] In the final position of the primary optics 100 on the substrate 200, the light exit portion 161 of the protrusion 160 of the primary optics 100 is positioned (positioned) such that the adhesive 400 directly covers the light exit portion 161. In other words, the adhesive 400 is disposed (positioned) between the substrate 200 and the light exit portion 161, as can be seen in FIG.

[0032] In a next step d), the UV adhesive 400 is cured by radiating UV light to the light incidence surface 170 of the fixing device 150. In this case, the holding element 180 and the protrusion 160 act as a light guide of the fixing device 150 and are configured to guide the UV light to the light emission part 161 of the protrusion 160 inside the primary optical system 100 in order to cure the UV adhesive 400. In the illustrated example, in particular the example shown in Fig. 3, the robot arm 500 comprises a UV light source 510 for radiating UV light to the light incidence surface 170, the UV light source 510 being configured as a spot type UV light source.

[0033] 3 shows an example of an exemplary light beam emitted by the UV light source 510 of the robot arm 500. In the figure, it can be seen that the light beam enters the light incident surface 170, is guided inside the primary optical system 100 and the protruding portion 160, reaches the light exit portion 161, and exits from the light exit portion 161 to cure the adhesive 400 (i.e., a line is shown which enters the light incident surface 170 from the UV light source 510, and reaches the light exit portion 161 after repeated reflection).

[0034] Optionally (if necessary), in a further step e), when the primary optical system 100 is in its final position on the substrate 200, additional adhesive (e.g., structural adhesive) is applied (applied or coated) into the fixing holes 210 to further strengthen the fixation of the primary optical system 100 in its final position.

[0035] Within the framework of the entire disclosure of the present invention (including the claims and drawings), modifications and adjustments of the embodiments are possible based on the basic technical ideas. Furthermore, within the framework of the entire disclosure of the present invention, various combinations or selections (including "non-selection") of the various disclosed elements (including each element of each claim, each element of each embodiment, each element of each drawing, etc.) are possible. In other words, the present invention naturally includes various modifications and alterations that a person skilled in the art would be able to make in accordance with the entire disclosure including the claims and drawings, and the technical ideas of the present invention.

[0036] Furthermore, the reference numerals in the drawings attached in the claims are intended solely to aid in the understanding of the invention, and are not intended to limit the invention to the embodiments and examples shown.

[0037] Furthermore, the entire contents of each of the above references are hereby incorporated by reference. [Explanation of symbols]

[0038] 10 Light Module 100 Primary optical system 110 Lens part 150 Fixation device 160 Protrusion 161 Light output part 170 Light incidence surface 180 Holding Element 200 Base 210 Fixed hole (fixed opening) 300 light source 400 Adhesive 500 Robot Arm 510 UV light source

Claims

1. A method for assembling a light module (10) for a motor vehicle headlamp, comprising the steps of: The method comprises the following steps, performed in the order listed: a) A primary optical system (100) including a lens portion (110) corresponding to a light source (300) and a fixing device (150), wherein the fixing device (150) includes at least one protrusion (160) and a light entrance surface (170) for receiving the curing light, and the at least one protrusion (160) includes a light exit portion (161) for emitting the curing light; a base (200) configured to hold at least one light source (300) and the primary optical system (100), the base (200) including at least one fastening hole (210) configured to receive at least one protrusion (160) of the primary optical system (100); At least one light source (300) arranged on the substrate (200); To provide: b) applying an adhesive (400) into at least one fastening hole (210) of said substrate (200); c) positioning the primary optical system (100) to a final position on the substrate (200) such that light emitted by the at least one light source (300) can be received by a lens portion (110) of the primary optical system (100), wherein in the final position at least one protrusion (160) of the primary optical system (100) is inserted into at least one fixing hole (210) of the substrate (200); d) curing the adhesive (400) by emitting curing light to a light incidence surface (170) of the fixing device (150), the fixing device (150) being configured to direct the curing light to a light exit portion (161) of a protrusion (160) within the primary optical system (100) to cure the adhesive (400); Contains A method comprising:

2. 10. The method of claim 1 , In step a), a robot arm (500) for holding the primary optical system (100) is further provided, wherein the fixing device (150) includes at least one holding element (180) configured to correspond to the robot arm (500) such that the robot arm (500) can engage with the at least one holding element (180) to hold the primary optical system (100); in step c), the robot arm (500) holds the primary optical system (100) via the holding element (180) and aligns the primary optical system (100). A method comprising:

3. 10. The method of claim 1 , The curing light is UV light. A method comprising:

4. 4. The method of claim 3, The UV light is generated by a spot-type UV light source. A method comprising:

5. 10. The method of claim 1 , The adhesive (400) is a UV adhesive. A method comprising:

6. 10. The method of claim 1 , The adhesive (400) is a hybrid adhesive. A method comprising:

7. 3. The method of claim 2, The robot arm (500) includes a UV light source (510). A method comprising:

8. 3. The method of claim 2, the robot arm (500) includes a UV adhesive device for applying UV adhesive to the at least one fixing hole (210) in step b); A method comprising:

9. 3. The method of claim 2, The primary optical system (100) includes at least two holding elements (180) arranged on opposite sides of the primary optical system (100) (across the lens portion (110)). A method comprising:

10. 3. The method of claim 2, said at least one retaining element (180) being configured as a protrusion (160); A method comprising:

11. 3. The method of claim 2, The at least one holding element (180) and / or the protrusion (160) function as a light guide for the curing light to guide the curing light from the light entrance surface (170) to the light exit portion (161) and out from the light exit portion (161). A method comprising:

12. 10. The method of claim 1 , The at least one light source (300) is configured as an LED. A method comprising:

13. The method according to any one of claims 1 to 12, In a further step e), when the primary optical system (100) is in its final position on the substrate (200), additional adhesive is applied to the fixing holes (210) to further strengthen the fixing of the primary optical system (100) in its final position. A method comprising:

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