Lighting module for use in a motor vehicle

Abstract

Lighting module (2) for use in the front area of a motor vehicle (80), comprising a first layer (4a) comprising a carrier unit (6), a second layer (4b) comprising a light module unit (8) arranged on the carrier unit (6) with a plurality of flexible printed circuit boards (10) and a plurality of light sources (12) electrically connected to the flexible printed circuit boards (10), and a third layer (4c) comprising a separator unit (14) for mechanical and / or thermal support and for electrical insulation, wherein the carrier unit (6) has an air duct system (16) for guiding an air flow (LS).

Description

[0001] Lighting module for use in a motor vehicle

[0002] Description

[0003] The invention relates to a lighting module for use in the front area of a motor vehicle and to a motor vehicle, comprising such a lighting module.

[0004] The use of display technologies as communication elements between motor vehicles and their surroundings has increased significantly in recent years. Displays are increasingly being integrated into modern headlights and car body lighting in particular to implement additional functions such as status indicators, communication signals, or brand-specific lighting effects. The display surfaces often follow complex, design-driven free-form geometries that adapt to the vehicle contour and allow a high degree of design freedom. Flexible printed circuits (FPCs) are increasingly being used to implement such free-form displays, as they can be adapted to curved or inclined surfaces.

[0005] With the increasing integration of display functions, the demands on their optical and technical performance are also growing. To ensure high resolution and good visibility in different environmental conditions, an increasing number of LEDs are required on an ever smaller area. This higher packing density leads to a significant increase in thermal stress within the module. If additional lighting requirements, such as daytime running light functions or communication signals with high luminous flux, are implemented via the same display area, the heat loss increases significantly.

[0006] The combination of high luminous flux requirements, complex free-form designs, and high LED packing density pushes conventional LED-equipped flexible conductor tracks to their thermal limits. Project-related constraints such as weight, installation space, and geometric specifications significantly limit the use of classic passive cooling concepts. In addition, efficient heat dissipation requires a functional thermalconnection between the heat sink and the flexible conductor, which can often only be achieved with additional components such as thermal paste or thermally conductive adhesive films. These, in turn, increase manufacturing costs and weight while reducing cooling performance due to additional contact resistance. Furthermore, passively cooled systems with large-area, thermally highly stressed FPCs often prove to be uneconomical and limited in their function.

[0007] It is therefore the object of the present invention to at least partially overcome the disadvantages known from the prior art. In particular, it is an object of the invention to provide a compact, active cooling concept for display applications in the vicinity of vehicle headlights, which, despite high thermal power density, enables efficient and uniform heat dissipation, while being space-saving, weight-optimized, and economical to manufacture.

[0008] The above task is solved by a lighting module with the features of claim 1 and a motor vehicle with the features of claim 13. Further features and details of the invention are apparent from the respective subclaims, the description, and the drawings. It is understood that features and details described in connection with the lighting module according to the invention also apply in connection with the motor vehicle according to the invention and vice versa.

[0009] According to a first aspect of the invention, a lighting module is provided for use in the front area of a motor vehicle. The lighting module according to the invention comprises a first layer comprising a carrier unit, a second layer comprising a light module unit arranged on the carrier unit with a plurality of flexible printed circuit boards and a plurality of light sources electrically connected to the flexible printed circuit boards, and a third layer comprising a separator unit for mechanical and / or thermal support and for electrical insulation, wherein the carrier unit has an air duct system for guiding an air flow.The lighting module according to the invention can be used in particular in the front area of a passenger car or truck. It goes without saying that use in the rear area or in the side areas of a passenger car or truck is also conceivable.

[0010] The combination of the first, second, and third layers provided by the invention, in particular in combination with the design in which the carrier unit has an air duct system for guiding an air flow, makes it possible in particular to provide a compact, active cooling concept for display applications in the vicinity of vehicle headlights, which enables efficient and uniform heat dissipation despite high thermal power density, while being space-saving, weight-optimized, and economical to manufacture. The carrier unit according to the invention fulfills a dual function here by not only mechanically stabilizing and protecting the second layer or the light module unit, but also ensuring the necessary heat dissipation from the light module unit.

[0011] With regard to ensuring mechanical protection and increasing the service life of an object lighting module, as well as homogeneous light distribution, it may be advantageous to provide that the second layer, comprising a light module unit arranged on the carrier unit, is arranged between the first layer and the third layer, preferably directly between the first layer and the third layer. In this context, the direct arrangement of the second layer between the first and third layers can preferably be understood to mean that the second layer is arranged with a first surface directly adjacent to the first layer and with the second surface arranged opposite directly adjacent to the third layer.

[0012] To ensure high thermal, electrical, and mechanical stability while maintaining low weight and good adhesion, it may also be advantageous if the carrier unit is made of a thermosetting plastic, preferably polyimide or epoxy resin.

[0013] To generate a simple application-specific adaptation of light distribution, with improved thermal behavior and material and energy savings, it may also be advantageous if the- 7 -

[0014] light sources are unevenly distributed within the second layer, with the areas with the highest light source density preferably being located centrally within the second layer.

[0015] In the context of providing particularly lightweight, energy-efficient, durable, flexible, and stylish lighting modules, especially for use in complex geometries, it may also be envisaged that the light sources are designed in the form of LEDs. It goes without saying that other light sources can also be used as alternatives, such as OLEDs, laser diodes, or EL films.

[0016] In order to achieve an ideal combination of thermal, mechanical, and electrical stability, it may be advantageous to provide that the third layer is made of a thermoplastic or thermosetting plastic, preferably an LCP or polyimide.

[0017] For effective heat dissipation from the light module unit, it may be particularly useful to provide that the air duct system has a plurality of air ducts which are preferably arranged parallel to one another and, in particular, run along the longitudinal direction of the carrier unit. Although the air channels, which preferably run close to the conductor tracks, reduce the volumetric air flow due to their smaller cross-section, they increase the air velocity and pressure. Both are necessary to guarantee the required cooling performance over long distances.

[0018] For the targeted distribution of an air flow to the air ducts, it can also be advantageous if the air duct system has an air inlet module for introducing air into the air ducts, wherein the air inlet module preferably has an inlet nozzle arranged at an angle to the air ducts for introducing cooling air and a cover arranged parallel to the air ducts for arrangement over the air ducts. The existing arrangement of air ducts makes it possible, in particular, to distribute the air flow to the air ducts in a targeted manner and thus also to distribute the air flow to the components to be cooled in a targeted manner.As part of a constructively simple, cost-effective, and reliable targeted distribution of an air flow to the air ducts, it may be advantageous to provide that the cover has an air inlet frame comprising a plurality of air inlet chambers, wherein preferably each air inlet chamber is connected to an air duct.

[0019] With regard to the targeted adaptability of the lighting module in question to geometric specifications and conditions, it may also be advantageous if the air inlet module and the air ducts are designed as two separate components that are preferably connected to each other in a form-fitting manner. For example, the individual components can be manufactured in different designs and combined with each other in different ways as required.

[0020] To ensure rapid and effective heat dissipation from the light module unit, it may also be advantageous to provide that a fan is provided for generating cooling air, wherein the fan is preferably arranged at the end of the inlet connection.

[0021] In the context of uniform light distribution, in particular targeted light control, it may be envisaged that an optical layer is provided for optical adaptation of emitted light.

[0022] The invention also relates to a motor vehicle comprising a lighting module as described above. The motor vehicle according to the invention thus offers the same advantages as those already mentioned in detail in relation to the lighting module according to the invention.

[0023] The invention is explained in more detail below with reference to the accompanying drawings.

[0024] These show:

[0025] Fig. 1 A schematic representation of an inventive lighting module for use in the front area of a motor vehicle in an exploded view,Fig. 2 a schematic representation of a first layer according to the invention, as seen in cross-section in the xz direction,

[0026] Fig. 3 a schematic representation of a lighting module for use in the front area of a motor vehicle according to a cross-section in the xy direction,

[0027] Fig. 4 A schematic representation of a motor vehicle according to the invention with a lighting module according to the invention.

[0028] In the following description of some embodiments of the invention, identical reference numerals are used for the same technical features in different embodiments.

[0029] Fig. 1 shows a schematic representation of an illumination module 2 according to the invention for use in the front area of a motor vehicle 80 in an exploded view.

[0030] As can be seen from Fig. 1 , the lighting module 2 has a first layer 4a comprising a carrier unit 6, a second layer 4b comprising a light module unit 8 arranged on the carrier unit 6 with a plurality of flexible printed circuit boards 10 and a plurality of light sources 12 electrically connected to the flexible printed circuit boards 10, and a third layer 4c comprising a separator unit 14 for mechanical and / or thermal support and for electrical insulation. The carrier unit 6 also has an air duct system 16 for guiding an air flow LS. In addition, an optical layer 4d is provided for optical adjustment of emitted light.

[0031] that the second layer (4b), comprising a light module unit (8) arranged on the carrier unit (6), is arranged between the first layer (4a) and the third layer (4c), preferably directly between the first layer (4a) and the third layer (4c).The carrier unit 6 can be made of a thermosetting plastic, preferably a polyimide or an epoxy resin.

[0032] The light sources 12 are in the form of LEDs and are unevenly distributed within the second layer 4b, with the areas with the highest light source density being centrally located within the second layer 4b (dashed area of layer 4b).

[0033] The third layer 4c can advantageously be made of a thermoplastic or thermosetting plastic, e.g., an LCP or polyimide.

[0034] Fig. 2 shows a schematic representation of a first layer according to the invention in cross-section in the xz direction.

[0035] As can be seen in Fig. 2, the air duct system 16 has a plurality of air ducts 16a, which in this case are arranged parallel to each other and run along the longitudinal direction of the carrier unit 6.

[0036] The cover 22 also has an air inlet frame 24, which has a plurality of air inlet chambers 24a, wherein preferably each air inlet chamber 24a is connected to an air duct 16a.

[0037] Fig. 3 shows a schematic representation of a lighting module for use in the front area of a motor vehicle according to a cross-section in the xy direction.

[0038] As can be seen in Fig. 3, the air duct system 16 also has an air inlet module 18 for introducing air into the air ducts 16a, wherein the air inlet module 18 in this case an inlet nozzle 20 arranged at an angle to the air ducts 16a for introducing cooling air and a cover 22 arranged parallel to the air ducts 16a for arrangement over the air ducts 16a.

[0039] Finally, it can be seen from Fig. 3 that a fan 28 is provided for generating cooling air, wherein the fan (28) is arranged at the end of the inlet nozzle 20.Fig. 4 shows a schematic representation of a motor vehicle 80 according to the invention with two headlights 60 and an illumination module 2 according to the invention.

[0040] The lighting module according to the invention makes it possible, in particular, to provide a compact, active cooling concept for display applications in the vicinity of vehicle headlights, which, despite high thermal power density, enables efficient and uniform heat dissipation and is space-saving, weight-optimized, and economical to manufacture.Reference list

[0041] 2 Lighting module

[0042] 4a First layer

[0043] 4b Second layer

[0044] 4c Third layer

[0045] 4d Optical layer

[0046] 6 Carrier unit

[0047] 8 Light module unit

[0048] 10 Flexible printed circuit board 12 Light source

[0049] 14 Separator unit

[0050] 16 Air duct system

[0051] 16a Airduct

[0052] 18 Air inlet module

[0053] 20 Inlet nozzle

[0054] 22 Cover

[0055] 24 Air inlet frame

[0056] 24a Air inlet chamber

[0057] 28 Fan

[0058] 60 Headlight

[0059] 80 Motor vehicle

[0060] LS Air flow

Claims

Lighting module for use in a motor vehicleClaims1. Lighting module (2) for use in the front area of a motor vehicle (80),comprising:- a first layer (4a) comprising a carrier unit (6),- a second layer (4b) comprising a light module unit (8) arranged on the carrier unit (6) with a plurality of flexible printed circuit boards (10) and a plurality of light sources (12) electrically connected to the flexible printed circuit boards (10),- a third layer (4c) comprising a separator unit (14) for mechanical and / or thermal support and for electrical insulation,characterized in thatthe carrier unit (6) has an air duct system (16) for guiding an air flow (LS).

2. Lighting module (2) according to claim 1 ,characterized in thatthe second layer (4b), comprising a light module unit (8) arranged on the carrier unit (6), is arranged between the first layer (4a) and the third layer (4c), preferably directly between the first layer (4a) and the third layer (4c).

3. Lighting module (2) according to claim 1 or 2,characterized in thatthe carrier unit (6) is made of a thermosetting plastic, preferably polyimide or epoxy resin.

4. Lighting module (2) according to one of the proceeding claims,characterized in thatthe light sources (12) are unevenly distributed within the second layer (4b), with the areas with the highest light source density preferably being locatedcentrally within the second layer (4b).

5. Lighting module (2) according to one of the proceeding claims,characterized in thatthat the light sources (12) are designed in the form of LEDs.

6. Lighting module (2) according to one of the proceeding claims,characterized in thatthat the third layer (4c) is made of a thermoplastic or thermosetting plastic, preferably an LCP or polyimide.

7. Lighting module (2) according to one of the proceeding claims,characterized in thatthat the air duct system (16) has a plurality of air ducts (16a) which are preferably arranged parallel to one another and, in particular, run along the longitudinal direction of the carrier unit (6).

8. Lighting module (2) according to claim 7,characterized in thatthat the air duct system (16) has an air inlet module (18) for introducing air into the air ducts (16a), wherein the air inlet module (18) preferably has an inlet nozzle (20) arranged at an angle to the air ducts (16a) for introducing cooling air and a cover (22) arranged parallel to the air ducts (16a) for arrangement over the air ducts (16a).

9. Lighting module (2) according to claim 7,characterized in thatthat the cover (22) has an air inlet frame (24) comprising a plurality of air inlet chambers (24a), wherein preferably each air inlet chamber (24a) is connected to an air duct (16a).

10. Lighting module (2) according to claim 8 or 9,characterized in thatthat the air inlet module (18) and the air ducts (16a) are designed as two separate components that are preferably connected to each other in a formfitting manner.

11. Lighting module (2) according to claim 9 or 10,characterized in thatthat a fan (28) is provided for generating cooling air, wherein the fan (28) is preferably arranged at the end of the inlet connection (20).

12. Lighting module (2) according to claim 9 to 11 ,characterized in thatthat an optical layer (4d) is provided for optical adaptation of emitted light.

13. Motor vehicle (80), comprising a lighting module (2) according to one of the preceding claims.

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