Light-emitting module and light-emitting device for automobiles

Abstract

The present invention relates to an automotive light emitting module (1) comprising: a first substrate including a first light source coupled to a first optical element (4); and a heat sink (5) arranged in thermal communication with the first substrate, the first optical element (4) comprising a main mounting element (6) configured to mount the first optical element (4) to the heat sink (5) without traversing the first substrate, the first substrate being held between at least a portion of the first optical element (4) and a portion of the heat sink (5).

Description

[Technical Field]

[0001] The present invention relates to the field of automotive lighting systems, and more particularly to the assembly of various components contained within automotive lighting systems. [Background technology]

[0002] Automotive lighting systems are increasingly requiring more electrical connections to control and power the light sources contained therein.

[0003] Furthermore, heat dissipation factors also play an important role in the operation of these devices. Since the performance of solid-state light sources such as light-emitting diodes (LEDs) is greatly affected by temperature, good heat dissipation is beneficial to the performance of optical devices.

[0004] These heat sinks are placed in thermal contact with different printed circuit boards. These assemblies also include printed circuit boards and reflectors. Bonding all these elements together requires ensuring their mechanical stability and precise relative positioning.

[0005] The joining operation typically involves drilling through holes in the printed circuit board and using bolts to secure the different elements together.

[0006] However, due to lack of space in modern designs, it is not always possible to provide such through holes in printed circuit boards.

[0007] Therefore, new solutions and designs are needed to solve this problem. Summary of the Invention

[0008] The present invention provides a solution to this problem by providing a light emitting module for an automotive lighting device. a first substrate including a first light source configured to emit light; a first optical element positioned to receive light emitted from the first light source and project the light; and a heat sink disposed in thermal communication with the first substrate, the heat sink configured to dissipate heat from the first substrate; The light emitting module is characterized in that the first optical element includes a primary mounting element configured to mount the first optical element to the heat sink without traversing the first substrate, the substrate being held between at least a portion of the first optical element and a portion of the heat sink.

[0009] Notably, the heat sink may include multiple fins.

[0010] As described above, the primary mounting element is configured to mount the first optical element to the heat sink without crossing the first substrate. In other words, the primary mounting element does not penetrate the first substrate. Therefore, the primary mounting element does not interfere with the corresponding first substrate and can avoid applying mechanical stress to the first substrate.

[0011] An optical element, as will be understood without further ado by those skilled in the art of automotive lighting, is an element that has some optical properties for receiving a light beam and outputting it in a certain direction and / or shape. Reflectors, collimators, light guides, projection lenses, etc., or combinations thereof, are some examples of these optical elements that are useful for converting the light beam emitted from the light source into a light pattern acceptable for the function selected for the lighting device.

[0012] These optical elements may define a focal point or focal line, which is the point or line along which light emitted by the light source is most effectively transmitted by the optical elements.

[0013] Such an arrangement provides a rigid mounting for the components included in the light emitting module (ie, the substrate, the optical element, and the heat sink), but does not require additional through holes in the substrate.

[0014] In some particular embodiments, a portion of the heat sink forms part of the frame of the first substrate.

[0015] This means that the heat sink material surrounds a portion of the first substrate, also in the substrate plane, around at least a portion of the edge of the first substrate. In some specific embodiments, the main mounting element includes a fastening portion and is joined to the remainder of the reflector portion by an arm. In some specific embodiments, the fastening portion is attached to the heat sink.

[0016] The fixing part is intended to form or receive a suitable fixing element, such as a screw or a bolt, and the connection by the arm is due to the fact that the connection is separate from the rest of the reflector element. In order to save material, the arm is therefore sufficient to transmit the holding force by this connection. In other embodiments, other types of fixing are also possible, for example by clipping hooks.

[0017] In some particular embodiments, the first optical element is a reflector that includes a first reflecting portion having a first reflecting surface that reflects light rays emitted by the first light source and defines a front side of the first reflecting surface.

[0018] In some particular embodiments, the arm is disposed on the first optical element behind the first reflecting portion and extends behind the first reflecting portion in a direction away from the first reflecting portion.

[0019] The front portion is defined by the light emission, and the rear portion is the portion opposite the front portion. In any case, it is known to those skilled in the art how to distinguish between the front and rear portions in a light emitting module such as one of the present invention.

[0020] The arms extend rearwardly away from the first reflecting portion so that the mounting of the first optical element does not interfere with the corresponding first substrate.

[0021] The first substrate may be an electronic substrate such as an electronic circuit board.

[0022] In some particular embodiments, the light emitting module comprises: a second substrate including a second light source configured to emit light; and further comprising a second optical element positioned to receive light emitted from the second light source and project the light; The primary mounting element is positioned to further mount the first optical element to the second optical element without being within the path of light rays emitted by the second light source and polarized by the second optical element. In some particular embodiments, the light emitting module further includes at least one auxiliary mounting element configured to mount the first optical element to the second optical element, holding the heat sink, the first substrate, and the second substrate between a portion of the first optical element and a portion of the second optical element.

[0023] The optical module with the second substrate and second optical element described above can have two different functions performed by light sources located on different substrates and emitting light to different optical elements. Although this embodiment is more complex, it is still advantageous because the present invention does not interfere with the complexity of the arrangement between these elements.

[0024] In some particular embodiments, the second optical element is a reflector that includes a second reflecting portion having a second reflecting surface that reflects light rays emitted by the second light source and defines a front of the second reflecting surface.

[0025] In some particular embodiments, the arm extends in the longitudinal direction at a level behind the second reflecting part, and the fixing part is attached to the second optical element behind the second reflecting part, so that, taking into account the longitudinal direction, in particular the direction corresponding to the main direction of the beam from the light emitting module, the arm extends far enough away from the first reflecting part so as to be attached to the second optical element behind the second reflecting part, i.e. on the rear side of the reflecting part.

[0026] In some specific embodiments, the second substrate is positioned in a plane parallel to the plane of the substrate, which facilitates light projection and coordination between light sources on the two different substrates.

[0027] In some particular embodiments, the light emitting module further includes an additional mounting element configured to mount the second optical element to the heat sink.

[0028] As mentioned above, operations using two substrates are more complicated and as such it may be desirable to create a partial mount such as attaching the second optical element to a heat sink.

[0029] In some particular embodiments, at least one auxiliary attachment element passes through a hole in the first substrate and / or passes through a hole in the second substrate. The present invention also allows for the case where several auxiliary mounting elements pass through holes in either board, which increases the designer's possibilities for placing various elements in the required space.

[0030] In some specific embodiments, the auxiliary mounting elements do not penetrate any holes in the substrate, and while the present invention can accommodate through holes as described above, it is also possible that all bonding occurs outside the projection of the substrate and does not traverse the substrate.

[0031] In some particular embodiments, the second substrate is disposed in a plane parallel to the plane of the substrate, but has at least a portion that does not coincide with the first substrate when projected onto the first substrate in a direction perpendicular to the plane of the first substrate.

[0032] This offset can be useful for optical reasons, for example if the focal placement on one side requires a different position than the focal placement on the other side, and can also be used to advantage to cleverly position the mount so that it does not interfere with other elements.

[0033] In some particular embodiments, the second optical element is positioned such that the second reflective portion is at least partially offset backward compared to the first reflective portion.

[0034] The present invention is particularly advantageous in such cases, because the two reflectors can be attached to each other, regardless of this offset, without interfering with the second reflector or the light beam reflected by it. Without the use of the present invention, if the first reflector were directly fastened to the second reflector, there would be a risk of some deformation of the second reflecting surface. This risk is avoided by the present invention.

[0035] This has the advantage that if the optical element has a focal length, the second optical element has a much longer focal length, which can be particularly advantageous if the second optical element is combined with a second light source to generate a segmented beam.

[0036] In some specific embodiments, the light source is a solid-state light source, such as a light-emitting diode. The term "solid-state" refers to light emitted by solid-state electroluminescence, which uses semiconductors to convert electricity into light. Compared to incandescent lamps, solid-state lighting generates less heat and dissipates less energy to produce visible light. Solid-state electronic lighting devices generally have a lower mass, making them more resistant to shock and vibration than fragile glass tubes / bulbs or thin filament wires. Eliminating filament evaporation also potentially extends the life of the lighting device. Some examples of these types of lighting include semiconductor light-emitting diodes (LEDs), organic light-emitting diodes (OLEDs), or polymer light-emitting diodes (PLEDs) as illumination sources, rather than electric filaments, plasmas, or gases.

[0037] In some particular embodiments, the main mounting element has a triangular shape, which provides a good compromise between mechanical strength and light weight.

[0038] In some particular embodiments, the main mounting element has reinforcing ribs, which also provide a good compromise between mechanical strength and light weight.

[0039] In some particular embodiments, the primary mounting element is configured between two fins of the heat sink. By disposing the primary mounting element between two fins of the heat sink, the fins extend on either side of the primary mounting element, allowing for offset fixation of the first optical element while enabling more heat exchange surface.

[0040] In a further inventive aspect, the present invention refers to a headlamp comprising a light emitting module according to the first inventive aspect.

[0041] In some particular embodiments, the light sources are light emitting diodes and the second substrate is configured to provide a matrix beam function.

[0042] Unless otherwise defined, all terms used herein (including technical and scientific terms) are to be interpreted in accordance with the common practice in the art. Furthermore, it will be understood that commonly used terms, unless expressly defined herein, should be interpreted in the common practice in the art, and should not be interpreted in an idealized or overly formal way. [Brief explanation of the drawings]

[0043] To complete the description and to provide a better understanding of the invention, a set of drawings are provided. The drawings form an integral part of this specification, illustrate one embodiment of the present invention, and should not be construed as limiting the scope of the invention, but merely as an example of how the invention may be practiced. The drawings include the following figures:

[0044] [Figure 1] FIG. 1 shows some elements of a first embodiment of an automotive lighting device according to the invention. [Figure 2]2 and 3 show transverse and longitudinal cross sections, respectively, of the optical module of FIG. 1 to show the internal elements of this light emitting module. [Figure 3] 2 and 3 show transverse and longitudinal cross sections, respectively, of the optical module of FIG. 1 to show the internal elements of this light emitting module. [Figure 4] FIG. 4 shows a headlamp comprising the light module according to the previous figures.

[0045] In these figures, the following reference numbers are used: 1 Light-emitting module 2 First Printed Circuit Board 3 LED on the first printed circuit board 4 First Reflector Assembly 5 Heatsink 6 Main mounting element 7 Fixing part of the main mounting element 8 Arm of main mounting element 9 Second Printed Circuit Board 10. Headlamp 11 LED on the second printed circuit board 12 Second Reflector Assembly 13 First auxiliary mounting element 14 Second auxiliary mounting element 15 Projection Lens Assembly 21 First reflector 22 Second reflector 100 Automobiles DETAILED DESCRIPTION OF THE INVENTION

[0046] The illustrated embodiments are described in sufficient detail to enable those skilled in the art to embody and practice the systems and processes described herein, and it is important to understand that the embodiments may be provided in many alternative forms and should not be construed as limited to the examples set forth herein.

[0047] Thus, while the embodiments can be modified in various ways and can take various alternative forms, specific embodiments are shown in the drawings and will be described in detail below by way of example. There is no intention to limit the invention to the particular forms disclosed. On the contrary, all modifications, equivalents, and alternatives falling within the scope of the appended claims are to be covered. Where appropriate, elements of the exemplary embodiments will be consistently designated by the same reference numerals throughout the drawings and the detailed description.

[0048] Fig. 1 shows a perspective view of an entire light emitting module according to the present invention, Fig. 2 and Fig. 3 show a horizontal cross section and a vertical cross section of the optical module of Fig. 1, respectively.

[0049] In this module 1 a first optical element (here a first reflector assembly 4 ), a heat sink 5 , a second optical element (here a second reflector assembly 12 ), and a projection lens assembly 15 can be seen.

[0050] The light module 1 also includes a printed circuit board and LEDs, which emit light that is projected by reflectors included in the first and second reflector assemblies 4, 12, respectively. However, these additional elements shown in other figures are hidden in the reflector assemblies 4, 12. The first reflector assembly 4 includes a first reflector portion 21 having a first reflective surface that reflects light emitted by the first group of LEDs 3 on the first printed circuit board 2 and defines a front of the first reflector assembly 4. Meanwhile, the second reflector assembly 12 includes a second reflector portion 22 having a second reflective surface that reflects light emitted by the second group of LEDs 11 and defines a front of the second reflector assembly 12.

[0051] 1 and 3 relate to the manner in which the first reflector assembly 4 is attached to the remaining elements of the optical module 1. FIG. The first reflector assembly 4 includes a main mounting element 6 configured to mount the first reflector assembly 4 to the heat sink 5 without crossing the first printed circuit board. This is done by means of arms 8 that connect the main mounting element 6 to the rest of the first reflector assembly 4, thereby ensuring mechanical stability of the joint. The main mounting element 6 includes fastening portions 7 suitable for receiving bolts to provide the joint.

[0052] As can be seen in Figures 1 and 3, the main mounting element 6 is positioned to further mount the first reflector assembly 4 to the second reflector assembly 12 without being within the path of the light rays emitted from the second group of LEDs 11 and deflected by the second reflector portion 22.

[0053] The first reflector assembly 4 further includes two other auxiliary mounting elements 13, 14 that bond the first reflector assembly 4 to the heat sink 5, except that in this case the bonding is done using two through holes in the first printed circuit board.

[0054] As can be seen in this figure, in this embodiment the main mounting element 6 has a triangular shape, with its base starting from the first reflector assembly 4 and its apex located at the fixing part 7. This main mounting element also has reinforcing ribs that maintain good mechanical properties without increasing the weight.

[0055] This main mounting element 6 can be seen to be housed between the fins of the heat sink, which means that it leaves the reflector area and penetrates into the heat sink area.

[0056] 2 and 3 show the internal elements of this light emitting module 1. FIG.

[0057] More specifically, the internal printed circuit boards are shown. First, a first printed circuit board 2 includes a plurality of LEDs 3 forming a first LED group. These LEDs 3 emit light that is projected by a plurality of reflectors of a first reflector portion 21 included in a first reflector assembly 4. A heat sink 5 is configured to dissipate heat from the first printed circuit board 2.

[0058] In this embodiment, the plurality of LEDs 3, together with the first reflector assembly 4 and the projection lens assembly 15, are responsible for providing a low beam function. This first printed circuit board 2 is crossed by two auxiliary mounting elements 13, 14 that attach the first reflector assembly (not shown in FIG. 2) to the heat sink 5, but is not crossed by the main mounting element 6 (not shown in FIG. 2). This main mounting element 6 attaches the first reflector assembly 4 to the heat sink 5, but does not drop onto any protrusions on the first printed circuit board 2. During this attachment process, the first printed circuit board 2 is held between at least a portion of the first reflector assembly 4 and a portion of the heat sink 5.

[0059] 2 and 3, there is also seen a second printed circuit board 9 and a second reflector assembly 12. This second printed circuit board 9 also contains an LED group 11 which, in this example, together with a second reflecting portion 22 of the second reflector assembly 12 and a projection lens assembly 15, is responsible for providing a matrix beam function.

[0060] As can be seen in FIG. 2 , in this embodiment, the auxiliary mounting elements 13, 14 not only mount the first optical element 4 to the heat sink 5, but also to the second reflector assembly 12, holding the heat sink 5, the first printed circuit board 2 and the second printed circuit board 9 between a portion of the first reflector assembly 4 and a portion of the second reflector assembly 12.

[0061] Additionally, although not visible in this view, the second reflector assembly 12 also includes a further mounting element configured to mount the second reflector assembly 12 to the heat sink 5 .

[0062] The second reflector assembly 12 is positioned such that the second reflective portion 22 is at least partially offset rearward compared to the first reflective portion 21. The present invention allows the two reflectors to be attached to each other despite this offset without interfering with the second reflective portion 22 or the light beam reflected thereby.

[0063] 4 shows a headlamp 10 including the light module 1 according to the previous figures. This headlamp 10 is mounted in a motor vehicle 100.

Claims

1. A light emitting module (1) for an automotive light emitting device, a first substrate (2) including a first light source (3) configured to emit light; a first optical element (4) arranged to receive light emitted from a first said light source (3) and to project said light; a heat sink (5) disposed in thermal communication with the first substrate (2), the heat sink (5) configured to dissipate heat from the first substrate (2); Equipped with the first optical element (4) includes a main mounting element (6) configured to mount the first optical element (4) to the heat sink (5) without traversing the first substrate (2); A light emitting module (1), characterized in that the first substrate (2) is held between at least a part of the first optical element (4) and a part of the heat sink (5).

2. 2. A light emitting module (1) according to claim 1, wherein a part of the heat sink (5) forms part of a frame of the first substrate (2).

3. The light emitting module (1) according to any one of claims 1 to 2, wherein the main mounting element (6) comprises a fixing part (7) joined to the remainder of the reflector part by an arm (8), the fixing part being attached to a heat sink (5).

4. The light-emitting module (1) according to any one of claims 1 to 3, wherein the first optical element (4) is a reflector including a first reflecting portion (21) having a first reflecting surface that reflects light rays emitted by the first light source (3) and defines a front side of the first reflecting surface.

5. The light-emitting module (1) of claim 4 when dependent on claim 3, wherein the arm (8) is arranged on the first optical element (4) behind the first reflecting portion (21) and extends in a direction away from the first reflecting portion behind it.

6. The light emitting module (1) according to any one of claims 1 to 5, wherein the light source is a solid-state light source.

7. The light emitting module (1) according to any one of claims 1 to 6, wherein the main mounting element (6) has a triangular shape.

8. A light emitting module (1) according to any one of claims 1 to 7, wherein the main mounting element (6) is located between two fins of the heat sink.

9. a second substrate (9) including a second light source (11) configured to emit light; a second optical element (12) positioned to receive light emitted from the second light source and to project said light; Furthermore, The light emitting module (1) according to any one of claims 1 to 8, wherein the main mounting element (6) is arranged to further mount the first optical element (4) to the second optical element (12) without being in the path of a light ray emitted from the second light source and deflected by the second optical element (12).

10. 10. The light emitting module (1) of claim 9, wherein the second optical element (12) is a reflector including a second reflecting portion (22) having a second reflecting surface that reflects light rays emitted by the second light source (11) and defines a front of the second reflecting surface.

11. The light-emitting module (1) according to claims 5 and 10, wherein the arm (8) extends longitudinally at a level rearward of the second reflecting portion (22), and the fixing portion (7) is attached to the second optical element (12) at the rear of the second reflecting portion.

12. 12. The light-emitting module (1) according to claim 10, wherein the second optical element (12) is arranged such that the second reflecting portion (22) is at least partially offset backward compared to the first reflecting portion (21).

13. 13. The light-emitting module (1) according to any one of claims 9 to 12, further comprising at least one auxiliary mounting element (13, 14) configured to mount the first optical element (4) and the second optical element (12) and to hold the heat sink, the first substrate (2) and the second substrate (9) between a portion of the first optical element (4) and a portion of the second optical element (12).

14. A headlamp comprising a light emitting module (1) according to any one of claims 1 to 13.

15. The headlamp of claim 14, wherein the light-emitting module is one of those described in any one of claims 9 to 13, and the second substrate includes light-emitting diodes configured to provide a matrix beam function.

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