Light Module Having a Plurality of Preliminary Lenses

Abstract

The invention relates to a light module for a motor vehicle headlamp that has semiconductor light sources and a primary lens unit, wherein the primary lens unit comprises preliminary lenses. The light deflection surfaces in the preliminary lenses each have a first subsection and second subsection, wherein the curvatures and/or slopes of the subsections differ, such that the directions of the optical axes in the first subsections differ from the directions of the optical axes in the second subsections.

Claims

1. A light module for a motor vehicle headlamp, said light module comprising: at least two semiconductor light sources, and at least one primary lens unit, wherein the primary lens unit includes at least two preliminary lenses, each dedicated to a respective semiconductor light source, wherein the preliminary lenses are adjacent to one another along a horizontal axis of the primary lens unit, and wherein each preliminary lens includes a light entry surface with a central light entry region and a peripheral light entry region, and a light deflection surface surrounding the peripheral light entry region, wherein the light deflection surfaces on each preliminary lens include a first subsection and second subsection, wherein the first subsection is closer to the center of the primary lens unit along the horizontal axis of the primary lens unit than the second subsection, and the second subsection is closer to an outer edge of the primary lens unit along the horizontal axis of the primary lens unit than the first subsection, wherein a curvature and/or slope of the first subsection is flatter than a curvature and/or slope of the second subsection, starting from the peripheral light entry region, and the curvature and/or slope of the second subsection is steeper than the curvature and/or slope of the first subsection, starting from the peripheral light entry region, such that a direction of a first optical axis of the first subsection differs from a direction of a second optical axis of the second subsection.

2. The light module as set forth in claim 1, wherein a low beam light distribution or a partial light distribution of a low beam light distribution is generated with the light module, such that light beams that are deflected at the first subsections of the preliminary lenses light a central region of the low beam light distribution on a measurement screen placed at a distance in front of the light module in a region surrounding the intersection (HV) of the horizontal axis (HH) and vertical axis (VV).

3. The light module as set forth in claim 2, wherein the light beams deflected at the second subsections of the preliminary lenses light a wide area along the horizontal axis of the low beam light distribution, wherein the wide area is wider horizontally than the central region lit by the first subsections.

4. The light module as set forth in claim 2, wherein each preliminary lens generates a partial light distribution of the low beam light distribution

5. The light module as set forth in claim 1, wherein the first subsections and second subsections of each preliminary lens transition smoothly into one another.

6. The light module as set forth in claim 1, wherein the light deflection surfaces of each preliminary lens are divided into the first subsection and second subsection along a vertical plane that is perpendicular to the horizontal axis, or along a diagonal plane in relation to the horizontal axis.

7. The light module as set forth in claim 1, wherein the primary lens unit comprises a preliminary lens located in the middle, between the at least two other preliminary lenses, wherein the middle preliminary lens comprises a symmetrical light deflection surface.

8. The light as set forth in claim 1, wherein there are between three and nine, particularly between five and seven, adjacent light sources, wherein the primary light unit includes between three and nine, particularly between five and seven, preliminary lenses, each of which is dedicated to a respective semiconductor light source.

9. The light module as set forth in claim 1, wherein the primary lens unit comprises a light emitting surface and the light emitting surface regions dedicated to the respective preliminary lenses transition smoothly into one another.

10. The light module as set forth in claim 1, wherein a second set of at least two adjacent preliminary lenses is located above or below the at least two preliminary lenses.

11. The light module as set forth in claim 10, wherein a high beam light distribution or a partial light distribution of a high beam light distribution is generated with the second set of preliminary lenses.

12. The light module as set forth in claim 1, further including a shutter assembly that includes a reflective shutter.

13. The light module as set forth in claim 1, further including a secondary lens having a projection lens.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Exemplary embodiments of the invention are illustrated in the drawings, and shall be explained in greater detail in the following description. Elements that have the same or similar functions have the same reference symbols in the drawings. Therein, schematically:

[0030] FIG. 1 shows a side view of a motor vehicle headlamp with a light module according to the invention according to a first embodiment;

[0031] FIG. 2 shows a side view of a light module according to the invention according to another embodiment;

[0032] FIG. 3 shows a primary lens for the light module according to the invention, shown in FIG. 2;

[0033] FIGS. 4A-4C show details of the primary lens shown in FIG. 3;

[0034] FIGS. 5A-5C show subsections of a light distribution from the light module according to the invention;

[0035] FIG. 6 shows a light distribution that can be generated with the light module according to the invention;

[0036] FIG. 7 shows a side view of another embodiment of the light module according to the invention;

[0037] FIGS. 8A-8C show different views of a primary lens for the light module according to the invention shown in FIG. 7; and

[0038] FIG. 9 shows a light distribution that can be generated with the light module according to the invention shown in FIG. 7.

DETAILED DESCRIPTION OF THE INVENTION

[0039] FIG. 1 shows a motor vehicle headlamp, indicated as a whole with the reference numeral 10. The motor vehicle headlamp 10 comprises a housing 12 that, in one embodiment, is made of plastic. The housing 12 has a light emitting hole 16 in the direction 14 in which light is emitted, which is covered by a transparent cover plate 18. The cover plate 18 is made of transparent plastic or glass. The plate 18 can be a clear plate with a surface that generates no optical effects. Alternatively, the plate 18 can have a surface with contours for generating optical effects (e.g. in the form of cylindrical lenses or prisms) which diffuse the light passing through it, preferably horizontally. The headlamp 10 is designed for installation in a motor vehicle. Two of these headlamps 10, placed on different sides of the motor vehicle, form a motor vehicle lighting assembly according to the invention. These headlamps are designed such that they appear to be symmetrical to one another.

[0040] A light module 20 is located inside the headlamp housing 12 in this example. As a matter of course, more than just the light module 20 shown here can be located in the headlamp housing 12. The light module 20 generates at least one light distribution that satisfies legal and regulatory requirements.

[0041] In the present example, the light module 20 is a light module according to the invention. The light module 20 shall be explained in detail below in reference to FIGS. 2 to 9.

[0042] The light module 20 is shown in a cutaway side view in FIG. 2.

[0043] The light module 20 comprises at least two adjacent semiconductor light sources 22. Only one of these semiconductor light sources 22 can be seen in FIG. 2.

[0044] The light module 20 also comprises at least one primary lens unit 24. The primary lens unit 24 comprises at least two preliminary lenses 26, each of which is dedicated to a respective semiconductor light source 22.

[0045] FIG. 3 shows an exemplary illustration of the primary lens unit 24. This primary lens unit 24 comprises seven preliminary lenses 26 in FIG. 3, which have the reference numerals 26-1 to 26-7. The primary lens unit 24 according to the invention comprises at least two, or between three and nine, particularly between five and seven, adjacent light sources 22 and at least two, or between three and nine, particularly between five and seven, preliminary lenses, each dedicated to a respective semiconductor light source 22.

[0046] It can be seen in FIG. 3 that the preliminary lenses 26 are adjacent to one another along the y-axis in the horizontal extension 28 of the primary lens unit 24.

[0047] Each preliminary lens 26 comprises a light entry surface 30, each of which has a central light entry region 32 and a peripheral light entry region 34. The light entry surface 30 is not indicated in all of the preliminary lenses in FIG. 3. The light entry surface 30 can be identical in all of the preliminary lenses 26.

[0048] According to this embodiment, the light entry surface 30 is rotationally symmetrical.

[0049] The central light entry region 32 forms a preliminary lens, by way of example. The peripheral light entry region 34 expands outward slightly from the central region 32, e.g. in the form of a funnel. Each peripheral light entry region 34 is surrounded by a light deflection region 36.

[0050] The light deflection surfaces 36 for the preliminary lenses 26-1, 26-2, 26-3, and 26-5, 26-6, 26-7 are not rotationally symmetrical. The preliminary lenses 26-1, 26-2, 26-3 and 26-5, 26-6, 26-7 can therefore be referred to as preliminary lenses with asymmetrical light deflection surfaces 36.

[0051] The asymmetrical light deflection surfaces 36 shall be explained below in reference to the preliminary lens 26-6 shown in FIGS. 4A to 4C. The explanations apply analogously to the preliminary lenses 26-5 and 26-7.

[0052] FIG. 4A shows the preliminary lens 26-6 as part of the primary lens 24. The light deflection region 36 in the preliminary lens 26-6 comprises a first subsection 38, shown in FIG. 4B, and a second subsection 40, shown in FIG. 4C. The first subsection 38 is closer to the center 42 of the primary lens unit 24 along the horizontal axis 28 than the second subsection 40. A center 42 is indicated by way of example in FIG. 3. This center does not have to be in the exact middle. Instead, a center in the framework of the invention is understood to be a point in the middle, in particular in relation to the horizontal plane, in the primary lens unit 24. The second subsection 40 is closer to the outer edge 44 of the primary lens unit 24 along the horizontal axis of the primary lens unit 24 than the first subsection 38. A curvature and/or slope of the first subsection 38 is flatter than the curvature and/or slope of the second subsection 40, starting from the peripheral light entry region 34. The curvature and/or slope of the second subsection 40 is steeper than the curvature and/or slope of the first subsection 38, starting from the peripheral light entry region 34.

[0053] In this example, the light deflection region 36 comprises curved surfaces. The light deflection region 36 can also comprise flat, slanted surfaces.

[0054] The first subsection 38 comprises a first optical axis 46. The second subsection comprises a second optical axis 48. As a result of the difference in the curvature and/or slope of the two subsections 38, 40, the direction of the first optical axis 46 in the first subsection 38 differs from the direction of the second optical axis 48 in the second subsection 40.

[0055] The deflection of the light in a direction differing from a main beam direction of the light module 20 is obtained in the light module 20 according to the invention by the design of the light deflection region 36 described here.

[0056] A low beam light distribution 50, shown in FIG. 6, can be obtained with the light module 20, by way of example.

[0057] The low beam light distribution 50 has a substantially horizontal light/dark boundary 52, which delimits the light distribution at the top, and is slightly above or below the horizontal plane, e.g. ±1°. The light/dark boundary 52 may be an asymmetrical light/dark boundary 52, i.e. it is higher on the side in the direction of travel than on the side directed toward oncoming traffic, in order to avoid blinding oncoming traffic. The transition in the light/dark boundary 52 between these sections, from the side in the direction of travel to the side directed toward oncoming traffic can have an arbitrary form, e.g. in the form of a steep diagonal or an abrupt step.

[0058] A shutter assembly 54 shown in FIG. 2, e.g. in the form of a reflecting shutter, is used to generate the light/dark boundary 52. The shutter assembly 54 is placed in the beam path of the light module 20. At least one surface of the shutter assembly 54 is reflective, by way of example.

[0059] The shutter 54 is placed in relation to a secondary lens 58, e.g. a projection lens, such that an edge 60 of the shutter assembly 54 defines the light/dark boundary in the low beam light distribution 50.

[0060] The low beam light distribution 50 in FIG. 6 is generated with the primary lens 24. The low beam light distribution 50 is generated by superimposing individual partial light distributions from each of the secondary lenses 26.

[0061] FIG. 5A shows a partial light distribution 62 in the low beam light distribution 60 generated with the preliminary lens 26-6.

[0062] Light beams that have been deflected at both subsections 38, 40 of the preliminary lens 26-6 are deflected in different directions because of the different optical axes 46, 48 of the two subsections 38, 40, and thus contribute to different portions of the low beam light distribution 50, or the partial light distribution 62 of the low beam light distribution.

[0063] Light beams deflected at the first subsection 38 of the preliminary lens 26-6 light a central region 64 in the low beam light distribution 50, or the partial light distribution 62, or a part thereof, where a horizontal plane H and vertical plane V intersect on a measurement screen placed at a distance in front of the light module 20.

[0064] The central region 64 spans the area ±15° along the horizontal axis on the measurement screen. The central region 64′ extends downward −10°, particularly −7° along the vertical axis from the light/dark boundary 52.

[0065] The first subsection 38 of the preliminary lens 26-6 lights a part 64 of the central region 64′, as shown in FIG. 5B. By way of example, the first subsection 38 lights an area between −12° and +7° along the horizontal axis and from −7° to the light/dark boundary 52 along the vertical axis. The first subsections 38 in the other preliminary lenses, e.g. 26-1, 26-2, 26-3, 26-5, 26-7, light other parts 64 of the central region 64′, each of which are offset thereto. The lighting of the entire central region 64′ in the low beam light distribution 50 shown in FIG. 6 is obtained by superimposing the parts 64 of the central region 64′ that are lit by the first subsections of the preliminary lenses 26 in the primary lens 24. The light beams deflected at the first subsections 38 therefore light a central region 64′ in the low beam light distribution 50.

[0066] Light beams deflected at the second subsection 40 of the preliminary lens 26-6 contribute to a wide area 66 in the low beam light distribution 50 or the partial light distribution 62, or a part thereof, along the horizontal axis, on a measurement screen placed at a distance in front of the light module 20. This wide area 66 is wider than the central region 64 lit by the first subsections 38 along the horizontal axis.

[0067] The wide area 66′ in the low beam light distribution 50 extends along the horizontal plane spanning the area ±45°, particularly ±35°. Along the vertical axis, the wide area 66′ extends from −15°, particularly −12°, to the light/dark boundary 52.

[0068] The second subsection 40 of the preliminary lens 26-6 lights a part 66 of the wide area 66′, as shown in FIG. 5C. By way of example, the second subsection 40 lights an area between −2° and +25° along the horizontal plane, and from −11° to the light/dark boundary 52 along the vertical plane. The other subsections 40 in the other preliminary lenses, e.g. 26-1, 26-2, 26-3, 26-5, 26-7 light other parts 66 of the wide area 66′, each of which are offset thereto. The lighting of the entire wide area 66′ in the low beam light distribution 50 shown in FIG. 6 is obtained by superimposing the parts 66 of the wide area 66′ lit by the second subsections of the preliminary lenses 26 in the primary lens 24. The second subsections 40 of the preliminary lenses 26 therefore produce a particularly wide fundamental light distribution in the low beam light distribution 50.

[0069] The slope and/or curvature of the first and second subsections 38, 40 of the preliminary lenses 26-1, 26-2, 26-3, 26-5, 26-6, 26-7 may vary. By way of example, this difference in this slope and/or curvature of the first and second subsections 38, 40 can be greatest in the outer preliminary lenses 26-1 and 26-7, and it can decrease toward the middle, up to the preliminary lenses 26-3 and 26-5.

[0070] The preliminary lenses 26-1, 26-2, 26-3 mirror those shown in FIGS. 5A to 5C, i.e. the first subsections 38 are on the right, and the second subsections 40 are on the left.

[0071] According to the embodiment shown here, the light deflection region 36′ in the preliminary lens 26-4, which is located in the middle of the preliminary lens 26, is rotationally symmetrical. This is not absolutely necessary, but may be advantageous for purposes of symmetry. The preliminary lens 26-4 is a preliminary lens with a symmetrical light deflection region 36′. By way of example, the light deflection region 36′ in the preliminary lens 26-4 lights the central region 52, or a part of the central region 52 in the low beam light distribution 50.

[0072] FIG. 7 shows another embodiment of the light module 20 according to the invention. In this embodiment, the primary lens 24 in the light module shown in FIG. 2 is supplemented with another set 68 of preliminary lenses 70. By way of example, another set 68 of at least two adjacent preliminary lenses 70 is placed below the preliminary lenses 26. Each of the preliminary lenses 70 in the second set is dedicated to at least one semiconductor light source 72. By way of example, a lower surface 56′ of the shutter assembly 54 forms a reflecting surface.

[0073] The primary lens 24 can therefore comprise two rows, one containing the preliminary lenses 26 and the other containing the preliminary lenses 70, as shown in FIGS. 8A to 8C. There can also be two separate primary lenses (not shown).

[0074] The primary lens 24 is shown in FIGS. 8A to 8C. The primary lens 24 comprises the preliminary lenses 26-1 to 26-7 in an upper row. The preliminary lenses 70-1 to 7-5 are located in a lower row.

[0075] The light deflection surfaces 36 and light entry surfaces 30 of the preliminary lenses 26-1 to 26-7 can be seen in FIG. 8A, in a view of the primary lens from behind. By way of example, the first and second subsections 38, 40 of the light deflection surfaces 36 are indicated in the preliminary lenses 26-1 and 26-7.

[0076] The preliminary lenses 70-1 and 70-5 can have the same fundamental design as the preliminary lenses 26-1 to 26-7. The preliminary lenses 70-1 to 70-5 also comprise light entry surfaces 30, for example. By way of example, the light deflection surfaces 74 in the preliminary lenses 70-1, 70-2, and 70-4, 70-5 can also comprise first and second subsections 76, 78.

[0077] The first subsection 76 is, like the first subsection 38, is closer to the middle 42 of the primary lens unit 24 along the horizontal axis 28 of the primary lens unit 24 than the second subsection 78.

[0078] A curvature and/or slope of the first subsection 76 is flatter than the curvature and/or slope of the second subsection, starting from the peripheral light entry region 34. In the second subsection 78, the curvature and/or slope is steeper than the curvature and/or slope of the first subsection 76, starting from the peripheral light entry region 34. As a result, the optical axes of the first and second subsections 76, 78 also differ analogously.

[0079] The subsections 76, 78 are designed such that a central region of a partial light distribution is lit with the first subsection 76, and a wider area of a partial light distribution is lit with the second subsection 78.

[0080] A partial light distribution for a high beam light distribution is generated with the second set 68 of preliminary lenses. By way of example, a partial light distribution can be generated with the second set 68 of preliminary lenses that supplements the low beam light distribution 50 in a region 80 lying above the horizontal plane to obtain a high beam light distribution 82, as shown in FIG. 9.

[0081] The first subsections 76 of the preliminary lenses 70-1, 70-2, and 70-4, 70-5 each light a part of the central region, which spans an area ±10° along the horizontal axis on a measurement screen, and extends to +5° above the light/dark boundary.

[0082] The second subsections 78 of the preliminary lenses 70-1, 70-2 and 70-4, 70-5 each light a portion of a wide area that spans an area ±22° along the horizontal axis on a measurement screen, and extends to +8° above the light/dark boundary.

[0083] The partial light distribution 80 is obtained by superimposing the parts lit by the first and second subsections 76, 78 of the preliminary lenses 70.

[0084] A middle preliminary lens 70-3 comprises a deflection region 84 in this example that is symmetrical over the vertical axis. In this case, the subsections 84′, 84″ are symmetrical in relation to a vertical plane 86.

[0085] By way of example, the two subsections 84′, 84″ in the preliminary lens 70-3 light the central region in the partial light distribution.

[0086] According to the embodiment shown here, the respective light deflection surfaces 36, 74, and 84 in the respective preliminary lenses 26, 70 are divided into the first and second subsections along a vertical plane 88 that is perpendicular to the horizontal axis 28, as shown in the illustration of the preliminary lens 70-1, by way of example. This division can also be along a plane that is diagonal to the horizontal axis 28.

[0087] The plane 88 does not have to pass through a middle point in the rotationally symmetrical light entry surface 30. The plane can also be displaced along the horizontal axis 28.

[0088] The first and second subsections in the preliminary lenses 26, 70 transition smoothly into one another. There are therefore no steps or edges in the respective light deflection surfaces 36, 74, 84 of the preliminary lenses 26, 70.

[0089] FIGS. 8B and 8C show the primary lens 24 from a perspective and from the front. The primary lens comprises an upper light emitting surface 90 and a lower light emitting surface 92 in the embodiment shown therein.

[0090] The light emitting surfaces 90, 92 can also be connected to form a joint light emitting surface.

[0091] The light emitting surface 90 comprises the light emitting surface sections 90-1 to 90-7. These are each dedicated to a preliminary lens 26-1 to 26-7. The light emitting surface 92 comprises light emitting surface sections 92-1 to 92-5. These are each dedicated to a primary lens 70-1 to 70-5. The light emitting surface regions 90-1 to 90-7 and 92-1 to 92-5 transition smoothly into one another. The primary lens 24 therefore comprises two smooth light emitting surfaces 90, 92. The light emitting surfaces 90, 92 on the primary lens 24 therefore do not any have steps or edges.

[0092] The invention has been described in an illustrative manner. It is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the invention may be practiced other than as specifically described.