SUPPORT FRAME FOR A VEHICLE LIGHTING DEVICE

Abstract

A support frame for components of a vehicle lighting device, especially for a housing or for a light module. The support frame features a sandwich structure of at least two metallic sheet members in parallel arrangement and at least one intermediate plastic joint member, which features form-locking joints with the sheet members.

Claims

1. A support frame for components of a vehicle lighting device, especially for a housing or for a light module, the support frame comprising: a sandwich structure formed of at least two metallic sheet members in parallel arrangement and at least one intermediate plastic joint member, which features form-locking joints with the sheet members.

2. The support frame according to claim 1, wherein at least one of the sheet members if formed of several sheet elements, which are overlapping in sections, wherein each sheet element features a form-locking joint with the joint member.

3. The support frame according to claim 1, wherein the support frame features at least one mount for mounting the components on the support frame and/or a mount for mounting the support frame on the vehicle or on the lighting device, wherein the mounts are sections of the sheet members and/or of the joint member.

4. The support frame according to claim 1, wherein the sheet members feature a U-profile or a L-profile at least in sections.

5. The support frame according to claim 1, wherein the sheet members feature an AlMg alloy and/or the joint member features an injection-moulded thermoplastic polymer.

6. A vehicle lighting device comprising at least one light module, wherein the lighting device comprises at least one support frame according to claim 1.

7. The vehicle lighting device according to claim 6, wherein the lighting device comprises a housing, which encloses the light module, wherein the housing is mounted on a housing support frame, and wherein the housing support frame is dedicated to be mounted on the vehicle.

8. The vehicle lighting device according to claim 6, wherein the lighting device features a module support frame, wherein the light module is mounted on the module support frame, and wherein the housing encloses the module support frame.

9. The vehicle lighting device according to claim 8, wherein the module support frame is mounted on the housing support frame by a mount, which extends through the housing.

10. The vehicle lighting device according to claim 6, wherein the lighting device comprises a front cover and a back cover, wherein the front cover encloses the light module, and wherein the front cover is mounted on a front side of the support frame and the back cover is mounted on a back side of the support frame, and wherein the support frame is dedicated to be mounted on the vehicle.

11. The vehicle lighting device according to claim 10, wherein the back cover is detachably mounted.

12. A method of manufacturing a support frame according to claim 1, the method comprising: providing the at least two metallic sheet members by punching and/or bending appropriate blanks; injection-moulding of a plastic component onto at least a first sheet member forming at least a first section of the joint member with form-locking joints with the first sheet member; and joining the second sheet member in a substantially parallel arrangement to the first sheet member forming the sandwich structure with the intermediate joint member.

13. The method according to claim 12, wherein joining of the second sheet member is performed by heat-staking or direct thermal joining forming form-locking joints between the second sheet member and the joint member or by adhesive bonding.

14. The method according to claim 12, wherein joining of the second sheet member is performed by injection-moulding of a plastic component onto the second sheet member forming a second section of the joint member with form-locking joints with the second sheet member, and/or welding together the first section and the second section of the joint member.

15. The method according to claim 12, wherein the step of providing of at least one of the sheet members is performed by arranging several sheet elements overlapping in sections.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] 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:

[0027] FIGS. 1a and 1b show perspective views of an example of the support frame;

[0028] FIGS. 2a and 2b show perspective views to illustrate the method of manufacturing the first support frame;

[0029] FIGS. 3a to 3d show perspective views of a housing mounted on the first support frame;

[0030] FIG. 4 shows a perspective view of an example of the lighting device;

[0031] FIGS. 5a to 5d show perspective views to illustrate the method of manufacturing an example of the support frame;

[0032] FIG. 6 shows a front view of an example of the lighting device;

[0033] FIGS. 7a to 7d show perspective views to illustrate the method of manufacturing an example of the support frame;

[0034] FIGS. 8a and 8b show perspective partial views of an example of the lighting device; and

[0035] FIG. 8c shows a cross-sectional view of the third lighting device.

DETAILED DESCRIPTION

[0036] FIG. 1a and FIG. 1b show perspective views of an example of the support frame 10 featuring a sandwich structure of the two metallic sheet members 1, 2 in parallel arrangement and the intermediate plastic joint member 3, which forms positive, i.e., form-locking joints with both sheet members 1, 2. The related FIG. 2a and FIG. 2b show a representation without the second sheet member 2 in order to illustrate the method of manufacturing the support frame 10.

[0037] The contour of the sheet members 1, 2 was formed by punching metallic blanks and the mount 4a in form of protruding lugs are produced by bending. The mount 4a are dedicated as interfaces for screw and plug connection to a housing of a vehicle lighting device. FIG. 2a and FIG. 2b show the state after injection-moulding of a plastic component onto the first sheet member 1 forming the joint member 3, wherein the form-locking joints are established by moulding the plastic component through the holes, which are distributed in roughly regular spacings along the sheet member 1. The joint member 3 features several interconnected honeycomb-like structures as well as the mount 4e in form of robust lugs for the setup of screw connections with the vehicle body. The second sheet member 2 features holes corresponding to the mount 4e and to the little studs protruding from the joint member 3 (see FIG. 2b), so that the second sheet member 2 can be brought in parallel arrangement to the first sheet member 1 and in contact with the border areas of the honeycomb structures of the intermediate joint member 3. The plastic studs extending through the holes of the second sheet member 2 are heated and deformed during a subsequent heat-staking process thus forming positive joints with the second sheet member 2.

[0038] The combined properties of the sheet members 1, 2 and the joint member 3 generate a highly robust support frame 10, which features distinct stiffness and endurance under stretching, shearing, bending or torsional loads.

[0039] FIGS. 3a-d show perspective views of a housing 20 mounted on the support frame 10, in such a way, that the support frame 10 encloses the housing 20. FIG. 4 shows a perspective view of a related vehicle lighting device 100, namely a headlight. The housing 20 encloses the light modules 30, which are mounted on a separate plastic module frame inside the housing 20. The mount 4e of the support frame 10 represent the interfaces for mounting the entire lighting device 100 to a respective vehicle body. In particular, the stiff sandwich structure of the support frame 10 is dedicated to replace a cross member of the vehicle body and thus serve as a structural body component.

[0040] FIGS. 5a-d show perspective views to illustrate the method of manufacturing a support frame 10, the sheet members of which is formed of several sheet elements 1a, 1b, 2a, 2b, which are overlapping in sections. The individual sheet elements 1a, 1b, 2a, 2b are exemplary punched metal parts partially reinforced by beads and with numerous holes for forming positive joints with the sections 3a, 3b of the joint member. The lugs with holes are dedicated to serve as a mount.

[0041] The initial arrangement of the sheet elements 1a, 1b with partial overlap constituting the first sheet member is shown in FIGS. 5a in top view and in FIG. 5b in side view. FIG. 5c shows the state after injection-moulding of a plastic component onto the first sheet member forming the first section 3a of the joint member with form-locking joints with the first sheet member, i.e., with each sheet element 1a, 1b. The matching second half of the support frame is manufactured likewise from the sheet members 2a, 2b and the injection-moulded second section 3b of the joint member. Afterwards the first section 3a and the second section 3b of the joint member are welded together in the welding plane 3c, for instance by means of laser welding or ultrasonic welding. Preferably, the dimensions of the first section 3a and the second section 3b are identical, i.e., the welding plane 3c represents the central plane of the support frame 10, so that warpage from volumetric shrinkage of the plastic component forming the first section 3a and the second section 3b can be mutually compensated.

[0042] FIG. 6 shows a front view of a lighting device 100, which features the housing 20 enclosing the light module 30, wherein the housing 20 is mounted on the housing support frame 10.1 and wherein the light module 30 is mounted on the module support frame 10.2, which is enclosed by the housing 20. Both support frames 10.1, 10.2 exemplarily correspond to the example as described in the context of FIGS. 5a-d. The housing support frame 10.1 is dedicated to be mounted on the vehicle body via the mount 4e. Both the housing support frame 10.1 and the module support frame 10.2 feature a mount 4b protruding inwards for mounting the module support frame 10.2 or the light module 30, respectively. Since all the mounts 4b, 4e are formed by lugs of the metallic sheet members, the lighting device 100 features a particularly stable and accurate positioning of the lighting module 30 relative to the corresponding vehicle body. The mount 4b of the housing support frame 10.1 extend through the housing 20, so that the housing 20 does not serve as load-bearing component, but only as a sealing for the interior of the lighting device 100.

[0043] FIGS. 7a-d show perspective views to illustrate the method of manufacturing an example of the support frame 10, the sheet members of which is formed of several sheet elements 1a, 1b, 2a, 2b, which are overlapping in sections. The individual sheet elements 1a, 1b, 2a, 2b are exemplary punched metal parts partially reinforced by beads and with numerous holes for forming positive joints with the sections 3a, 3b of the joint member. The lugs with holes are dedicated to serve as a mount 4a.

[0044] The initial arrangement of the sheet elements 1a, 1b with partial overlap constituting the first sheet member is shown in FIGS. 7a in top view. FIG. 7b shows the state after injection-moulding of a plastic component onto the first sheet member forming the first section 3a of the joint member with form-locking joints with the first sheet member, i.e., with each sheet element 1a, 1b. The first section 3a of the joint member features the mount 4c in form of a gutter-like receptacle for insertion of a housing. The matching second half of the support frame 10 is manufactured likewise from the sheet members 2a, 2b and the injection-moulded second section 3b of the joint member. Afterwards the first section 3a and the second section 3b of the joint member are welded together in the welding plane 3c.

[0045] FIG. 8a and FIG. 8b show perspective partial views and FIG. 8c shows a cross-sectional view of a related example of the vehicle lighting device 100. In FIG. 8b some sections of the support frame 10 are hidden for the purpose of clarity. The lighting device 100 features a front cover 21 and a back cover 22, wherein the front cover 21 encloses the light module 30, and wherein the front cover 21 and the light module 30 are mounted on a front side of the support frame 10, and wherein the back cover 22 is mounted on a back side of the support frame 10, and wherein the support frame 10 is dedicated to be mounted on the vehicle.

[0046] The joint member 3 features the channelled, gutter-like mount 4c as receptacle on the front side for the edge of the front cover 21 as well as the collar-like mount 4d for the back cover 22. The joints between the joint member 3 and the covers 21, 22 can exemplarily be reinforced by a glue.

[0047] 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.