LIGHT MODULE, HEADLIGHT, MOTOR VEHICLE AND METHOD FOR PRODUCING THE LIGHT MODULE

Abstract

A light module for a headlight of a motor vehicle, the light module having: a circuit board having at least one illuminating device for emitting light, wherein the circuit board has a longitudinal extent along a Y-axis, a width extent, extending perpendicular to the longitudinal extent, along an X-axis, and a vertical extent, extending perpendicular to the longitudinal extent and the width extent, along a Z-axis; a reflector; and a heat sink on which the circuit board is fastened. The heat sink is fastened to the reflector via a first fastener in such a manner that the first fastener secures a first referencing structure and/or a second referencing structure of the reflector against the circuit board such that the at least one illuminating device is located in a reference position in the direction of the Y-axis and in the direction of the X-axis relative to the reflector.

Claims

1. A light module for a headlight of a motor vehicle, the light module comprising: a circuit board having at least one illuminating device to emitt light, wherein the circuit board has a longitudinal extent along a Y-axis, a width extent, extending perpendicular to the longitudinal extent, along an X-axis, and a vertical extent, extending perpendicular to the longitudinal extent and the width extent, along a Z-axis; a reflector; and a heat sink on which the circuit board is fastened, the heat sink being fastened to the reflector via a first fastener such that the first fastener secures a first referencing structure and/or a second referencing structure of the reflector against the circuit board such that the at least one illuminating device is located in a reference position in the direction of the Y-axis and in the direction of the X-axis relative to the reflector.

2. The light module according to claim 1, wherein the first fastener is a screw mounted in a thread of the reflector.

3. The light module according to claim 2, wherein a clamping force, imparted by the screw, between the heat sink and the reflector secures the first referencing structure and/or the second referencing structure of the reflector against the circuit board.

4. The light module according to claim 1, wherein the reflector has the first referencing structure formed as a projection extending from the reflector in the direction along the Z-axis, and/or wherein the reflector has the second referencing structure formed as a projection extending from the reflector (20) in the direction along the Z-axis.

5. The light module according to claim 1, wherein the first referencing structure is disposed in a first recess of the heat sink and is placed against a wall of the circuit board so that the first referencing structure is placed against the circuit board in a direction along the Y-axis and/or along the X-axis.

6. The light module according to claim 5, wherein the first referencing structure is placed against a wall of a notch-shaped recess of the circuit board.

7. The light module according to claim 1, wherein the second referencing structure is disposed in a third recess of the circuit board and is placed against a wall of the third recess, so that the second referencing structure is placed against the circuit board in a direction along the Y-axis and/or along the X-axis.

8. The light module according to claim 1, wherein the heat sink is formed as a cooling plate or as a cooling sheet.

9. The light module according to claim 1, wherein the circuit board is fastened to the heat sink by at least one second fastener such that the at least one illuminating device is located in a reference position in the direction along the Z-axis relative to the reflector.

10. A headlight for a motor vehicle comprising a headlight housing, a light-transmitting headlight cover lens disposed on the headlight housing, and a light module according to claim 1.

11. A motor vehicle comprising at least one headlight according to claim 10.

12. A method for producing a light module according to claim 1, the method comprising: fastening the circuit board to the heat sink; and fastening the heat sink to the reflector via a first fastener such that the first referencing structure and/or the second referencing structure of the reflector are secured against the circuit board so that the at least one illuminating device is located in the reference position in the direction of the Y-axis and in the direction of the X-axis relative to the reflector.

13. The method according to claim 12, wherein the method further comprises: moving the heat sink relative to the reflector when the heat sink is fastened to the reflector via the first fastener such that the first referencing structure and/or the second referencing structure of the reflector are placed against and secure the circuit board fastened to the heat sink.

14. The method according to claim 12, wherein the first fastener is a screw which is mounted in a thread of the reflector, and wherein the method further comprises: inserting the screw through a through hole in the heat sink and screwing the screw into the thread of the reflector; and tightening the screw on the heat sink to fasten the heat sink to the reflector such that a torque applied to the screw takes along the heat sink relative to the reflector in the direction of rotation of the screw and thereby places and secures the first referencing structure and/or the second referencing structure against the circuit board.

15. The method according to claim 12, comprising a plurality of first fasteners that fasten the heat sink to the reflector, the fastener is fastened first that causes the first referencing structure and/or the second referencing structure to be placed against and to secure the circuit board.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0042] 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:

[0043] FIG. 1 shows a perspective view of a light module according to an exemplary embodiment of the invention;

[0044] FIG. 2 shows a bottom view of the light module from FIG. 1;

[0045] FIG. 3 shows the bottom view of the light module from FIG. 2 with an indication of the difference relative to the prior art; and

[0046] FIG. 4 shows a front view of a motor vehicle according to an exemplary embodiment of the invention.

DETAILED DESCRIPTION

[0047] FIG. 1 shows a perspective view of a light module 10 according to an exemplary embodiment of the invention. Light module 10 has a reflector 20, a heat sink 40, and a circuit board 30. Here, reflector 20 has reflector parts 25.1, 25.2, each of which has a separate reflector surface 21.1, 21.2. Alternatively, reflector 20 can have only one reflector part 25 having a reflector surface 21 or multiple reflector parts 25 having reflector surfaces 21.

[0048] A coordinate system with axes perpendicular to one another is depicted at the bottom right in FIGS. 1 and 2. The axes perpendicular to one another are an X-axis, a Y-axis, and a Z-axis. Each of these axes has two directions along the axis that are opposite to one another. The X-axis has the directions X.1, X.2, the Y-axis has the directions Y.1, Y.2, and the Z-axis has the directions Z.1, Z.2.

[0049] As can be seen in FIG. 2, reflector parts 25.1, 25.2 have a common reflector base body 22 or reflector 20 has a reflector base body 22. Reflector base body 22 extends in the direction X.2 away from reflector parts 25.1, 25.2. Reflector parts 25.1, 25.2 or reflector surfaces 21.1, 21.2 extend in the direction Z.1 according to their height. Further, reflector 20 has a first referencing structure 23 and a second referencing structure 24 extending as projections from reflector 20 in the direction Z.2. In the present case, the projections are shaped as prongs. In this case, one each of first referencing structure 23 and second referencing structure 24 is located on or near one each of reflector parts 25.1, 25.2.

[0050] Heat sink 40 is formed as a cooling plate, in particular as a cooling sheet. Heat sink 40 has a first recess 41 in the form of a hole and a second recess 42 in the form of a hole, as can be seen in FIG. 2. Further, heat sink 40 has a front section 43 and a back section 44. Back section 44 is located in front of reflector surfaces 21.1, 21.2 in the direction X.1 corresponding to the direction of the light reflected from reflector surfaces 21.1, 21.2, and thus not in an area of the light reflected from reflector 20. Reflector 20 is fastened to back section 44 of heat sink 40 via second fastener 2.1, 2.2, 2.3. Front section 43, in contrast, is located behind reflector surfaces 21.1, 21.2 in the direction X.1. Thus, illuminating device 31.1, 31.2 on circuit board 30, fastened to front section 43 of heat sink 40, can emit light onto reflector surfaces 21.1, 21.2. Front section 43, unlike back section 44, thus lies in the area of the light reflected from reflector 20.

[0051] Circuit board 30 has two illuminating device 31.1, 31.2. Only one illuminating device 31 or multiple illuminating device 31 can also be provided. This can be the case in particular with only one reflector surface 21. Circuit board 30 also has further electric elements 32, 33, such as, for example, a resistor 32 and a temperature sensor 33. Illuminating device 31.1, 31.2 are located opposite a contact surface of circuit board 30 placed against heat sink 40. A connector 34 is located on circuit board 30 for connecting a power supply source for supplying power to illuminating device 31.1, 31.2.

[0052] Circuit board 30 is fastened to heat sink 40 by a plurality of second fastener 1.1, 1.2, 1.3, 1.4. In the present case, second fastener 1.1, 1.2, 1.3, 1.4 are rivets. Via second fastener 1.1, 1.2, 1.3, 1.4, a reference position of circuit board 30 is made with illuminating device 31.1, 31.2 relative to reflector 20 in the direction Z.1. In this reference position or location of circuit board 30, circuit board 30 cannot be moved with respect to reflector 20. This is achieved by also having heat sink 40 being fastened to reflector 20 or their common reflector base 22. This becomes clear from FIG. 2.

[0053] FIG. 2 shows a bottom view of the light module from FIG. 1. Heat sink 40 is shown only with its outlines or transparent, so as not to obscure the view of reflector 20, lying below it in this perspective, or of reflector base body 22.

[0054] Reflector base body 22 or reflector 20 is connected to heat sink 40 via three first fastener 2.1, 2.2, 2.3, screws in the present case. The number of first fastener 2.1, 2.2, 2.3 can be varied. Via this fastening, heat sink 40 is set or referenced relative to reflector 20 in each of the directions along all of the axes X, Y, and Z. The reference position in direction Z.1 of circuit board 30 with respect to reflector 20 is thereby ensured via heat sink 40. Fastening of circuit board 30 to reflector 20 to set the reference position in the Z.1 direction does not occur. No area is provided on circuit board 30 for this purpose, as will be discussed in more detail later with reference to FIG. 3.

[0055] First referencing structure 23 of reflector 20 is passed through first recess 41 of heat sink 40 and is placed against a wall of a notch-shaped recess 36 of circuit board 30, so that heat sink 40 is fixed or referenced to reflector 20 in the Y.1 direction and the X.1 direction. This occurs in the assembly process via screw 2.1. When screw 2.1 is tightened in a thread in reflector 20 or reflector base body 22, the applied torque takes along heat sink 40 and thereby places circuit board 30, fastened to it, against first referencing structure 23. Of the plurality of screws 2.1, 2.2, 2.3 fastening heat sink 40 to reflector 20, screw 2, in the present case screw 2.1, is tightened first, which is the one that causes the torque applied to it during tightening to move heat sink 40 and thus circuit board 30 in the direction of first referencing structure 23 and/or second referencing structure 24, and to place and secure them against circuit board 30.

[0056] The clamping force of screw 2.1 secures the contact of first referencing structure 23 and/or second referencing structure 24 with circuit board 30, and thus provides a static overdetermination of the system. The direction of rotation of screw 2 can also be selected accordingly for the referencing. Thus, a left-hand or right-hand thread can be used to specify the direction in which heat sink 40 is taken, when screw 2 is tightened, and thus screw 2 to be tightened first. Here, first recess 41 is formed elongated or as an elongated hole. This enables ample compensation of manufacturing tolerances for guiding the projection therein.

[0057] Further, second referencing structure 24 of reflector 20 is passed through second recess 42 of heat sink 40 and a third recess 35 of circuit board 30 and is placed against a wall of third recess 35, so that circuit board 30 is fixed or referenced to reflector 20 in the Y.1 direction and the X.1 direction. Referencing in a direction along the Z-axis of circuit board 30 at reflector 20 or reflector base body 22 does not take place, because no surface of circuit board 30 opposite thereto is provided for this purpose, in order to keep circuit board 30 small and inexpensive. This is illustrated in FIG. 3.

[0058] FIG. 3 shows the bottom view of light module 10 from FIG. 2 with an indication of the difference to the prior art. Potential fastening positions 5.1, 5.2, 5.3, selected as examples, on circuit board 30 indicate that it is not possible to fasten circuit board 30 to reflector 20 at this location, which would enable the required reference position to be established in the direction of the Z-axis, because such a fastening would be in the area of the light reflected from reflector 20.

[0059] To fasten circuit board 30 to reflector 20, circuit board 30 would have to be considerably enlarged. The contours of such an enlarged circuit board 30, as would be used in accordance with the prior art, are shown as an outline 4 in FIG. 3. The outline 4 would then extend correspondingly to screws 2.1, 2.2, 2.3 in order to fasten circuit board 30 together with heat sink 40 and reflector 20 in the direction along all axes X, Y, Z. This requires a very large circuit board 30, which is correspondingly expensive. Via the solution presented here, in contrast, circuit board 30 can be produced much smaller, as shown in FIG. 3, in order to save costs.

[0060] FIG. 4 shows a front view of a motor vehicle 60 according to an exemplary embodiment of the invention. Motor vehicle 60 has two headlights 50.1, 50.2 according to an exemplary embodiment of the invention. Headlights 50.1, 50.2 each have light module 10 from FIG. 1, a headlight housing 51.1, 51.2, and a headlight cover lens 52.1, 52.2.

[0061] 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.