Method for producing an optical component, optical component and illuminating device for a motor vehicle

Abstract

A method for producing an optical component for an illuminating device of a motor vehicle, the optical component having at least one structured surface, comprising the following method steps: generating a first virtual representation of the surface that is to be structured of the component, applying a grid of points to the virtual representation of the surface that is to be structured of the component, shifting all or a plurality of the points in a randomized manner in the positive or negative direction in parallel with the respective normals to the surface in order to structure the surface, creating a second virtual representation of the surface that reproduces the structuring achieved by the shifting of the points, and producing the component on the basis of the second virtual representation of the surface.

Claims

1. A method for producing an optical component for an illuminating device of a motor vehicle, the optical component comprising at least one structured surface, the method comprising: generating a first virtual representation of the surface that is to be structured of the component; applying a grid of points to the virtual representation of the surface that is to be structured of the component; shifting all or a plurality of the points in a randomized manner in a positive or negative direction in parallel with respective normals to the surface in order to structure the surface; creating a second virtual representation of the surface that reproduces the structuring achieved by the shifting of the points; and producing the component on the basis of the second virtual representation of the surface.

2. The method according to claim 1, wherein the extent of the shifting in parallel with the respective normals to the surface differs between at least two points and/or wherein the distance differs between at least individual adjacent points.

3. The method according to claim 1, wherein the randomized shifting of the points and/or the distance between at least individual adjacent points is based on a statistical distribution or a normal distribution.

4. The method according to claim 3, wherein the modulation bandwidth of the statistical distribution, in particular the variance of the normal distribution, has a different magnitude at least at two locations on the surface.

5. The method according to claim 1, wherein the second virtual representation of the surface, which reproduces the structuring achieved by the shifting of the points, is a NURBS surface.

6. An optical component for an illuminating device of a motor vehicle, the component being produced by the method according to claim 1, the component comprising: at least one structured surface; a plurality of depressions and elevations formed in the at least one structured surface whose extent is distributed in parallel with the respective normal to the surface and/or whose distance from one another is randomly distributed.

7. The optical component according to claim 6, wherein the component is an at least partially transparent component through which light passes, such as a lens or a prism, or that the component is a component from which light can be reflected, such as a mirror.

8. A plurality of optical components according to claim 6, wherein the components have identically or substantially identically structured surfaces.

9. An illuminating device for a motor vehicle, comprising an optical component according to claim 6.

10. The illuminating device according to claim 9, wherein the illuminating device is a headlamp to generate a cutoff line and/or a headlamp to generate a matrix high beam.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:

(2) FIG. 1 is a schematic view of a virtual representation of a surface to be structured of a component with a grid of points using a method according to the invention;

(3) FIG. 2 is a section according to line II-II in FIG. 1;

(4) FIG. 3 is a section according to line III-III in FIG. 1;

(5) FIG. 4 is a schematic view of an illuminating device according to the invention;

(6) FIG. 5 is a schematic representation of a light distribution generated by an illuminating device for a motor vehicle, wherein the illuminating device does not comprise an optical component according to the invention;

(7) FIG. 6 is a schematic representation of a first light distribution generated by an illuminating device for a motor vehicle according to the invention;

(8) FIG. 7 is a schematic representation of a second light distribution generated by an illuminating device for a motor vehicle according to the invention;

(9) FIG. 8 is a schematic representation of a third light distribution generated by an illuminating device for a motor vehicle according to the invention;

(10) FIG. 9 is a schematic representation of a light distribution generated by an illuminating device for a motor vehicle, wherein the illuminating device does not comprise an optical component according to the invention;

(11) FIG. 10 is a schematic representation of a fourth light distribution generated by an illuminating device for a motor vehicle according to the invention; and

(12) FIG. 11 is a schematic representation of a fifth light distribution generated by an illuminating device for a motor vehicle according to the invention.

DETAILED DESCRIPTION

(13) In a method according to the invention, a first virtual representation of a surface 1 to be structured of an optical component is generated. The first virtual representation 1 can be a computer graphic. In the exemplary embodiment shown in FIG. 1, the surface 1 is flat. However, the surface can be curved, for example, non-spherically curved.

(14) The first virtual representation of the surface 1 is provided with a grid of points 2. The points 2 each have a distance dx in a first direction x and a distance dy in a second direction y, perpendicular to the first direction x. Adjacent points 2 can each be at the same distance dx, dy from one another. However, it is also possible that the distance between at least individual adjacent points 2 is different. For example, the distance between at least individual adjacent points 2 can be based on a statistical distribution, in particular a normal distribution.

(15) In a third direction z, perpendicular to the first and the second directions x, y, the points 2 are shifted randomly upwards or downwards. The magnitude dz of the shifting is also randomly distributed, in particular according to a normal distribution. It is possible to shift all of the points 2 randomly upwards or downwards, or only some of the points 2.

(16) The shifting of the points 2 results in a dot grid that is partially above and below the first representation of the surface 1. Via the use of NURBS (Non-Uniform rational B-Splines), a second virtual representation of the surface 1 is generated from the dot grid, which is shown in FIG. 1 to FIG. 3. The second virtual representation 1 may also be a computer graphic. Due to the design of the second virtual representation of the surface 1 as a NURBS surface, this representation can be considered as a CAD specification in the design of the optical component and provide for the desired scattering effect.

(17) FIG. 2 and FIG. 3 show how the points 2 lying next to each other in the x-direction and in the y-direction are shifted to a greater or lesser extent in the positive or negative z-direction. The randomized shifting of all or a majority of the points in the positive or negative z-direction and the connection of the points 2 creates a surface 1 with more or less pronounced depressions 3 and elevations 4.

(18) FIG. 4 shows an example of an illuminating device according to the invention. The illuminating device comprises a light source 5 and a schematically shown optical component 6 which serves as primary optics. The exit surface of the component 6, which is formed as a plane surface 1, is a structured surface 1 produced by the method according to the invention.

(19) The illuminating device further comprises a shutter 8 projecting from below into the light 7 emanating from the primary optics, which shutter 8 serves as a cutoff contour to be imaged. Furthermore, the illuminating device comprises an optical component 9 which is arranged behind the shutter 8 and serves as output coupling optics and whose curved exit surface is also a structured surface 1′ produced by the method according to the invention.

(20) It is certainly possible to provide only the component 6 or only the component 9 with a structured surface 1, 1′.

(21) FIGS. 5 to 11 show examples of light distributions of illuminating devices with and without components having structured surfaces.

(22) FIG. 5 shows a horizontal edge 10 of a light distribution 11, for example a cutoff line of a low beam, wherein the illuminating device generating the light distribution 11 has no structured surface. The horizontal edge 10 is therefore not softened.

(23) FIG. 6 shows a horizontal edge 12 of a light distribution 13, for example a cutoff line of a low beam, wherein the light distribution 13 is generated by an illuminating device according to the invention with a component 6, 9 having a structured surface 1, 1′. The horizontal edge 12 is greatly softened.

(24) FIG. 7 shows another light distribution 14 generated by an illuminating device according to the invention with a component 6, 9 having a textured surface 1, 1′. This light distribution 14 has a slightly softened horizontal edge 15.

(25) FIG. 8 shows a further light distribution 16 generated by an illuminating device according to the invention with a component 6, 9 having a structured surface 1, 1′. The light distribution 16, serving for example as a low beam, has a homogenized area 17.

(26) FIG. 9 shows a light distribution 18 in the form of a matrix light, for example, which has both a horizontal edge 19 and vertical edges 20. In this case, the illuminating device generating the light distribution 18 does not have a structured surface. The horizontal edges 19 and the vertical edges 20 are therefore not softened.

(27) FIG. 10 shows a light distribution 21 corresponding to the light distribution 18 in FIG. 8, which is generated by an illuminating device according to the invention with a component 6, 9 having a structured surface 1, 1′. In the light distribution 21, the vertical edges 22 are softened.

(28) FIG. 11 shows a light distribution 23 corresponding to the light distribution 18 in FIG. 8, which is generated by an illuminating device according to the invention with a component 6, 9 having a structured surface 1, 1′. In the light distribution 23, the horizontal edges 24 are softened.

(29) It is certainly possible to generate comparable light distributions with an illuminating device according to the invention in which both the vertical edges and the horizontal

(30) The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.