METHOD FOR INJECTION MOULDING A LIGHT MODULE FOR A LIGHTING DEVICE OF A MOTOR VEHICLE

Abstract

A method for producing a light module for a lighting device of a motor vehicle, wherein the module comprises a support component and a light-outcoupling component. According to the invention, a connection element for establishing a retaining connection between the support component and the light-outcoupling component is molded at least onto the support component by means of an injection molding process.

Claims

1. A method for producing a light module for a lighting device of a motor vehicle, the method comprising: providing the light module with a support component and a light-outcoupling component; and molding a connection element to establish a retaining connection between the support component and the light-outcoupling component at least onto the support component by an injection-molding process.

2. The method according to claim 1, wherein the support component and the light-outcoupling component are provided and inserted into an injection mold, and wherein the connection element is subsequently molded onto the support component and onto the light-outcoupling component forming the retaining connection.

3. The method according to claim 1, wherein the support component is provided and inserted into an injection mold, wherein the connection element is subsequently molded onto the support component forming the retaining connection, and wherein the light-outcoupling component is molded as a section of the connection element.

4. The method according to claim 3, wherein the injection molding of the connection element and/or the light-outcoupling component is carried out in one cycle or in several cycles.

5. The method according to claim 1, wherein the support component and/or the light-decoupling component are each provided with at least one connecting section, and wherein the connecting sections are molded by the connection element forming a form fit.

6. The method according to claim 5, wherein the at least one connecting section of the support component and/or the light-outcoupling component are provided with at least one undercut and/or with at least one opening.

7. The method according to claim 1, wherein, accompanying the injection molding of the connection element, at least one reference element is molded onto the module for reference to the lighting device.

8. The method according to claim 7, wherein the support component is provided with at least one hole, and wherein the hole is overmolded to form the reference element.

9. The method according to claim 7, wherein the reference element is molded in the form of a cone.

10. The method according to claim 1, wherein the light-outcoupling component is provided or molded in the form of a lens.

11. The method according to claim 1, wherein the connection element is molded with at least one cladding section, and wherein the cladding section envelops the support component at least in sections.

12. A light module for a lighting device of a motor vehicle, the light module comprising: a support component; and a light-outcoupling component, wherein the module is produced by the method according to claim 1.

13. The light module according to claim 12, wherein the support component comprises a metal and/or a metal alloy.

14. The light module according to claim 12, wherein the support component comprises an aluminum alloy.

15. The light module according to claim 12, wherein the connection element and/or the light-outcoupling component comprise a thermoplastic material.

16. The light module according to claim 12, wherein the connection element and/or the light-outcoupling component comprise a polycarbonate and/or a polymethyl methacrylate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] 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:

[0021] FIG. 1a shows a cross-sectional view of a first module according to the invention, and

[0022] FIG. 1b shows a cross-sectional view of a second module according to the invention

[0023] FIG. 2 shows a cross-sectional view of a third module according to the invention.

DETAILED DESCRIPTION

[0024] FIGS. 1a, 1b and 2 show cross-sectional views of three different embodiments of the light module 100 according to the invention. The module 100 comprises the support component 1 with the connection element 3 molded at the connecting section 11, which forms the retaining connection between the support component 1 and the light-outcoupling component 2. The three-dimensional shape of the support component 1 is essentially rotationally symmetrical about the longitudinal axis and the light-outcoupling component is formed as a lens 20 in each case. The support component 1 is preferably made of a light aluminum alloy.

[0025] The modules 100 shown in FIGS. 1a and 1b have been produced according to an embodiment of the method according to the invention, in which both the support component 1 and the light-outcoupling component 2 are provided as prefabricated components and inserted into the injection mold used in a target positioning to each other. In the subsequent injection molding process, the connection element 3, for example made of a thermoplastic, is then molded between the support component 1 and the light-outcoupling component 2 to produce the retaining connection.

[0026] The connection element 3 forms form-fitting connections with the respective connecting sections 11, 21. The connecting section 11 extends, in particular in full, along the final section of the support component 1 shown in the figures above and comprises circumferentially spaced openings 12, which are positively overmolded by the connection element 3. In addition, or alternatively, the surface of the connecting section 11 may be at least partially provided with undercut surface structures to further strengthen the connection between the support component 1 and the connection element 3. On the side of the light-outcoupling component 2, the connecting section 21 is formed as a, for example, fully circumferential collar for the formation of a spring-groove connection with the connection element 3. The light-outcoupling component 2 is formed, for example, from an optical glass, but usually from a transparent thermoplastic, wherein the connection element 3 is preferably formed from the same plastic to optimize the thermo-mechanical properties of the compound.

[0027] In the embodiment of module 100 shown in FIG. 1b, the connection element 3 additionally comprises the cladding section 31, which fulfills a design function of the connection element 3 as an external cover of the support component 1. This may serve in particular to achieve a certain color impression by using a suitably colored plastic for producing the connection element 3 and is expedient if the support component 1 is visible from the outside in the provided lighting device. Preferably, no form-fitting connection is established between the support component 1 and the cladding section 31, so that no undesirable interactions in the course of thermal expansion can occur.

[0028] The module 100 shown in FIG. 2 has been produced according to a second variant of the method according to the invention, in which only the support component 1 is provided as a prefabricated component and inserted into the injection mold used. Only during subsequent injection molding is the light-outcoupling component 2 formed as a section of the connection element 3, wherein the connection element 3 forms a form-fitting, retaining connection of the aforementioned type with the support component 1. The light-outcoupling component 2 is formed here material-uniformly with the remaining connection element 3 and can be molded depending on the thickness of the lens 20 or depending on the required optical quality in one or more cycles. In multi-stroke injection molding, for example, a punch that can be moved in the injection mold can be used.

[0029] All modules shown in the three figures comprise reference elements 4, which are used for referencing on the lighting device and are molded onto the support component 1 accompanying the injection molding of the connection element 3. For this purpose, the support component 1 with the holes 14 is provided, and these are either dimensionally overmolded as shown in FIG. 2 under formation of the reference elements 4 or used as shown in FIGS. 1a and 1b for molding a cone 40. The reference elements 4 are used in the assembly process of module 100 in the associated lighting device for referencing, for example on a support frame or directly at the light source.

[0030] Due to the precision and reproducibility of the injection molding process used both for establishing the retaining connection between the support component 1 and the light-outcoupling component 2 and for the molding of the reference elements 4, the light modules according to the invention 100 have a high tolerance quality and thus enable a significant simplification of the assembly and adjustment process in the construction of the associated automotive lighting device.

[0031] The invention is not limited in its embodiments to the preferred embodiment given above. Rather, a number of variants is conceivable, which makes use of the presented solution even with fundamentally different designs. All features and/or advantages resulting from the claims, the description or the drawings, including constructive details, spatial arrangements and method steps, can be essential both by themselves and in the most diverse combinations of the invention.

[0032] 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.