METHOD OF MANUFACTURING A BLINKER MODULE AS WELL AS A BLINKER MODULE, REARVIEW DEVICE AND MOTOR VEHICLE

Abstract

A method for manufacturing a blinker module for a rearview device of a motor vehicle includes the steps of providing at least one lighting element comprising at least one light guide and at least one light disk or lens and providing of at least one illuminant unit comprising at least one illuminant, wherein the illuminant unit is designed to couple light emitted by the illuminant into the lighting element. A blinker module, rearview device and motor vehicle, including the blinker module manufactured according to the method, are also described.

Claims

1. A method for manufacturing a blinker module for a rearview device of a motor vehicle, the method comprising: providing a lighting element comprising a light guide and a light disk or lens; providing an illuminant unit comprising an illuminant, wherein the illuminant unit is designed to couple light emitted by the illuminant into the lighting element; and arranging an insert between the light guide and the light disk or lens, the insert being designed as a cover or opaque design element, wherein at least one of the shape of the cover or opaque design element, color of the cover or opaque design element, or a pattern on the cover or opaque design element is suited to provide at least one of a logo, an emblem, a flag, a symbol or an information as an imprint on the insert, wherein a portion of the insert is inserted into a recess of a blinker module housing.

2. The method according to claim 1, wherein the insert is attached to the blinker module housing using welding.

3. The method according to claim 2, wherein the insert is inserted into the recess of the blinker module housing prior to being welded to the blinker module housing at a position within the recess of the blinker module housing.

4. The method according to claim 1, wherein the recess of the blinker module housing is located below the lower edge or side of the light guide.

5. The method according to claim 1, wherein the insert extends along the upper side of the light guide.

6. The method according to claim 1, wherein the insert contacts and supports the light guide.

7. The method according to claim 1, wherein at least one of the light guide and the insert taper in the direction of the illuminant unit along a part of the extension along the light propagation direction starting from the illuminant unit.

8. The method according to claim 1, wherein the illuminant unit, the lighting element, or both the illuminant unit and the lighting element are attached to the blinker module housing.

9. The method according to claim 1, wherein a circuit board of the illuminant unit is attached to the blinker module housing.

10. The method according to claim 1, wherein the insert is arranged to overlap at least partly, an end portion of or a middle portion of the light guide.

11. The method according to claim 1, wherein the insert is arranged to extend along the contour of at least one edge or side of the light guide along the light propagation direction starting from the illuminant unit.

12. The method according to claim 1, wherein the insert is arranged to be slotted along the contour of at least one edge or side of the light guide along the light propagation direction starting from the illuminant unit.

13. The method according to claim 1, wherein the insert is arranged to cover or screen the illuminant.

14. The method according to claim 1, wherein the insert includes an imprint which can only be seen in daylight.

15. The method according to claim 1, wherein the lighting element includes a coating applied by spraying, steaming, gluing, painting, or injection.

16. A rearview device for a motor vehicle comprising: an upper casing; a lower casing; and at least one blinker module attached between the upper and the lower casings or to the upper casing, the at least one blinker comprising: a lighting element comprising a light guide and a light disk or lens; an illuminant unit comprising an illuminant, wherein the illuminant unit is designed to couple light emitted by the illuminant into the lighting element; and an insert positioned between the light guide and the light disk or lens, the insert being designed as a cover or opaque design element, wherein at least one of the shape of the cover or opaque design element, color of the cover or opaque design element, or a pattern on the cover or opaque design element is suited to provide at least one of a logo, an emblem, a flag, a symbol or an information as an imprint on the insert, wherein a portion of the insert is positioned within a recess of a blinker module housing.

17. The rearview device according to claim 16, wherein the insert is attached to the blinker module housing using welding.

18. The rearview device according to claim 17, wherein the insert is inserted into the recess of the blinker module housing prior to being welded to the blinker module housing at a position within the recess of the blinker module housing.

19. The rearview device according to claim 16, wherein the recess of the blinker module housing is located below the lower edge or side of the light guide.

20. The rearview device according to claim 16, wherein the insert extends along the upper side of the light guide.

21. The rearview device according to claim 16, wherein the insert contacts and supports the light guide.

22. The rearview device according to claim 16, wherein at least one of the light guide and the insert taper in the direction of the illuminant unit along a part of the extension along the light propagation direction starting from the illuminant unit.

23. The rearview device according to claim 16, wherein the illuminant unit, the lighting element, or both the illuminant unit and the lighting element are attached to the blinker module housing.

24. The rearview device according to claim 16, wherein a circuit board of the illuminant unit is attached to the blinker module housing.

25. The rearview device according to claim 16, wherein the insert is arranged to overlap at least partly, an end portion of or a middle portion of the light guide.

26. The rearview device according to claim 16, wherein the insert is arranged to extend along the contour of at least one edge or side of the light guide along the light propagation direction starting from the illuminant unit.

27. The rearview device according to claim 16, wherein the insert is arranged to be slotted along the contour of at least one edge or side of the light guide along the light propagation direction starting from the illuminant unit.

28. The rearview device according to claim 16, wherein the insert is arranged to cover or screen the illuminant.

29. The rearview device according to claim 16, wherein the insert includes an imprint which can only be seen in daylight.

30. The rearview device according to claim 16, wherein the lighting element includes a coating applied by spraying, steaming, gluing, painting, or injection.

31. A method for manufacturing a blinker module for a rearview device of a motor vehicle, the method comprising: providing a blinker module housing; attaching a lighting element to the blinker module housing, the lighting element comprising a light guide and a light disk or lens; attaching an illuminant unit to the blinker module housing, wherein the illuminant unit comprises an illuminant and is designed to couple light emitted by the illuminant into the lighting element; attaching an insert to the blinker module housing by welding the insert to the housing, wherein the insert is arranged between the light guide and the light disk or lens, the insert being designed as a cover or opaque design element.

32. The method of claim 31, wherein the insert is welded to the housing below the lower edge or side of the light guide.

33. The method of claim 31, wherein the insert is welded to the housing both above and below the light guide.

34. The method of claim 31, wherein attaching the insert to the blinker module housing further includes inserting the insert into a recess of a blinker module housing prior to welding the insert to the housing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0054] Further features and advantages of the disclosure result from the following description, in which embodiments of the disclosure are explained by means of schematic drawings and diagrams. They show with

[0055] FIG. 1 is a schematic partial exploded representation of a blinker module according to a first embodiment of the disclosure;

[0056] FIG. 2 is a schematic representation of an inventive rearview device with the blinker module according to FIG. 1;

[0057] FIG. 3 is a flow chart of a method for producing the blinker module of FIG. 1;

[0058] FIG. 4 is an exploded representation of a blinker module according to a second embodiment of the disclosure;

[0059] FIG. 5a is a front view on the blinker module of FIG. 4;

[0060] FIG. 5b is a cross-section taken along the line AA of FIG. 5a;

[0061] FIG. 6 is an isometric view of the blinker module of FIG. 4;

[0062] FIG. 7 is a perspective view of a rearview device with the blinker module of FIG. 4;

[0063] FIG. 8a is a rear view on a part of a blinker module according to a third embodiment of the disclosure, with the housing being detached;

[0064] FIG. 8b is an enlargement of a part of FIG. 8a;

[0065] FIG. 9a is an isometric view of a part of the blinker module of FIGS. 8a and 8b installed in a rearview device, with a first insert;

[0066] FIG. 9b is a view similar to FIG. 9a, but with a second, slotted insert; and

[0067] FIG. 9c is a view similar to FIG. 9a, but with an insert of reduced size.

DETAILED DESCRIPTION

[0068] FIG. 1 shows a blinker module 1 according to a first embodiment of the disclosure, in a partial exploded representation.

[0069] The blinker module 1 comprises a lighting element 3, which has a light guide with a light disk that is an integral part of it. The blinker module 1 further comprises a illuminant unit 5, which has at least one illuminant 7, for example in the form of an LED, which is arranged on a circuit board 8. The light emitted by the illuminant unit 5 is coupled into the light guide at a first end 9 of the lighting element 3 and then propagates in the light guide. By means of the light disk, a planar illumination impression along the light guide is achieved. The schematic view in FIG. 1 is shown from the direction of oncoming traffic. The lighting element 3 has a flat front part (in FIG. 1 in the drawing plane). However, any other surface shapes are also possible.

[0070] In an end section 11 of the lighting element 3, which is opposite the first end 9, the lighting element 3 tapers in the course of a transition region 13 from a first, for example vertically wide, extension to a second, for example vertically narrower, extension.

[0071] The transition region 13 is followed by a first surface region 15 of the lighting element 3. In FIG. 1, this first surface region 15 is represented by a dashed rectangle. The first surface region 15 completely surrounds the lighting element 3. In FIG. 1, however, only the part of the first surface region 15 of the front part of the lighting element 3 is visible. A first coating element 17 is arranged on the first surface region 15. The first coating element 17 is arranged directly on the lighting element and is designed as a reflector layer. The latter has the purpose that light propagated within the lighting element 3, especially within the light guide, from the first end 9 towards the opposite end cannot escape from the lighting element 3 in the region of the first surface region 15. Instead, in the region of the first surface region 15, the light is reflected back into the lighting element through the reflector layer. This ensures that sufficient light intensity is available for the part of the end section 11 located to the right of the first surface region in FIG. 1. This divides the lighting element 3 into a first light region (in FIG. 1 left of the first surface region 15) and a second light region (in FIG. 1 right of the first surface region 15). The lower loss of light intensity in the lighting element 3 caused by the first coating element 17 leads to a homogeneous, or at least more homogeneous, illumination of the lighting element 3.

[0072] On a second surface region 19 (which coincides with the first coating element 17 shown in FIG. 1) of the first coating element 17, a second coating element 21 is directly arranged. While the first coating element 17 circumferentially surrounds the lighting element 3, the second surface region 19 only covers a part of the region of the first surface region 15, namely the part on the front of the lighting element 3, because the second coating element 21 no longer needs to prevent light from escaping from the lighting element 3 and/or the light from the lighting element 3 can be absorbed by the second coating element 21. The function of preventing or at least reducing this is assumed by the first coating element 17 according to the disclosure. Rather, it serves to form a cover in order to be able to interact with a casing of a rearview device in a suitable manner. For this purpose, the second coating element 21 is designed as an exposed element in the form of a cuboid in order to achieve a flush finish. The expansion of the exposed element is perpendicular to the drawing plane of FIG. 1 and is not shown in FIG. 1.

[0073] FIG. 2 shows a rearview device 23 according to the disclosure in a schematic representation. The rearview device 23 is shown from the direction of oncoming traffic, i.e. with the side facing away from the driver.

[0074] The rearview device 23 includes a blinker module, in particular a blinker module 1 as described above in relation to FIG. 1. Therefore, for better understanding, identical elements of the blinker module used in FIG. 2 as those of blinker module 1 in FIG. 1 are also marked with identical reference signs. The blinker module is mounted from inside the casing 25 of the rearview device 23. The housing 25 comprises at least one upper casing 27, also called scalp, and at least one lower casing 29, also called saber. The second coating element 21 is flush with the upper and lower casings 27, 29 at the top and bottom. In addition, almost any configuration of the second coating element 21 can be made as long as the blinker module 1 can only be arranged within the housing 25 of the rearview device 23.

[0075] FIG. 3 shows a flowchart 100 of an method according to the disclosure.

[0076] In one step 101, a lighting element, in particular a lighting element 3, is provided. This comprises a light guide and a light disk. The providing of the lighting element includes the step of forming the lighting element by injection molding. Both the light guide and the light disk are formed in one piece.

[0077] In a step 103, a first coating element, in particular the first coating element 17, is arranged on the lighting element on a first surface region, in particular the first surface region 15, of the lighting element. The arranging of the first coating element includes the step of forming the first coating element on the lighting element by injection molding. In other words, the first coating element is injection-molded onto the lighting element formed in step 101 in the first surface region and thus formed on the one hand and arranged directly on the lighting element on the other.

[0078] In a step 105, a second coating element, in particular the second coating element 21, is placed on the first surface element on a second surface region of the first surface element. The arranging of the second coating element includes the step of forming the second coating element on the first surface region by injection molding. In other words, the second coating element is injection-molded onto the first surface element formed in step 103 in the second surface region and thus formed on the one hand and arranged directly on the first surface element on the other hand.

[0079] In the following, with reference to FIGS. 4 to 5b, an alternative blinker module 50 of the present invention is described.

[0080] Turning to FIG. 4, the blinker module 50 comprises a housing 51 to which a circuit board 58 of an illuminant unit 55 and an outer lens 60 is to be attached, in particular in order to provide a sealed module. For that purpose a gasket may be arranged between the lens 60 and the housing 51 or the lens 60 may be welded to the housing 51. Between the lens 60 and the housing 51, are a light guide 53 and an inserter or inner cover 65. The light guide 53, the insert 65 and the lens 60 together provide a lightening element.

[0081] In FIGS. 5a and 5b the relative arrangement of the parts of the blinker module 50 can be seen. In particular, it can be seen in FIG. 5b that the insert 65 partly overlaps the light guide 53 and is attached to a recess 56 of the housing 51. In addition, the light guide 53 also engages the housing 51.

[0082] The circuit board 58 may carry two LED as illuminants, which emit light into the light guide 53. The light guide 53 may be provided with vertical radiator bar optics. The lens 60 may be formed out of crystal clear PMMA with no optics. The housing 51 may be black, in particular gloss polish. The insert 65 can be provided as a gloss black screen into which an emblem, logo or like, as shown for example in FIGS. 6 and 7, is printed. Thus, the insert 65 may be black in the inside, facing the light guide 53, in order to cover the light guide 53 such that no illumination will pass the insert 65 with its imprint. Accordingly, the imprint can only be seen at day light, but not at night, even when light is emitted into the light guide 53.

[0083] The flag or any other pattern may be provided on the insert 65 by pad printing. Such a printing process is especially facilitated by the fact that the insert 65 is provided with a mail geometry on the side facing the lens, allowing a mass production in cost saving manner.

[0084] FIG. 6 provides an isometric view of the assembled blinker module 50, which is bent in adaption to the contour of the scalp of a rearview device 70 as can be better seen in FIG. 7. The insert 65 is only arranged at one end of the light guide 53 and does not follow the same around the scalp of the rearview device 70.

[0085] FIG. 7 shows the arrangement of the blinker module 50 within the scalp, that is between an upper casing 75 and a lower casing 77. The blinker module 50 extends along a part of the circumference of the scalp in order to function as a blinker, that is as a side turn indicator, and as a design element by providing a design feature in form of the Italian flag which is printed on the insert 65.

[0086] FIGS. 8a and 8b show a third embodiment of a blinker module, being an alternative to the blinker module 50 and similar parts are provided with the same reference number hyphenated.

[0087] Turning now to FIG. 8a, it can be seen that two illuminants 57′ in form of LEDs are provided on a printed circuit board 58′ in order to emit light into the light guide 53′ provided with a texture 54′ in form of radiator bar optics to enhance homogeneity of the illumination along the path from the illuminants 57′ to the opposite end of the light guide 53. The light being reflected within the light guide 53′ is further propagating until said opposite end of the light guide 53′ in order to fulfill the blinker function.

[0088] At the end next to the illuminants 57′ an insert 65′ is arranged between the light guide 53′ and the outer lens 60′. Said insert 65′ is carrying an imprint of the Italian flag on the side facing the outer lens 60′ such that the blinker module 50′ fulfills a further design feature, namely displaying the Italian flag in case the illuminants 57 are switched off.

[0089] The position of the insert 65′ and the flag thereon can be offset 1 mm to the outer lens 60′, in order to avoid a direct contact. This gap is important for the manufacturing proses, in particular when the lens 60′ is welded to the housing.

[0090] With respect to FIGS. 9a to 9c different insert geometries are described in the following:

[0091] FIG. 9a shows the design discussed with respect to FIGS. 8a and 8b using a relative large insert 65′. Such an insert 65′ can be attached to the housing (not shown in FIG. 9a) in the area around the light pipe 53′.

[0092] In the alternative of FIG. 9b, the insert 65″ is provided with a slot 66″ along the upper contour or edge of the light guide 53″ at the end facing the illuminants 57″ such that light passes through the slot 66″ and the outer lens 60′ along the light guide 53″ as an additional design feature, when the illuminants are switched on.

[0093] Thus, even in case it is dark outside, the flag on the insert 65″ can be seen when the light guide 53″ is illuminated.

[0094] The insert 65″ can be attached to the housing (not shown) above and below the light guide 53″.

[0095] Turning now to FIG. 9c, the insert 65′ has a reduced size in order to just reach the upper edge of the light guide 53″ for allowing more light to pass the lens 60′″ above the flag on the insert 65′, while no light passes below the flag, as the insert 65′″ is attached to the not shown housing below the light guide 53″.

[0096] Thus, FIG. 9a provides an insert 65′ as a full cover of the light guide 53′ in the flag area to prevent flag illumination. The modified insert 65″ of FIG. 9b is provided with a tapering slot for additional shielding of stray light just allowing a sharp illumination of the contour of the light guide 53″, whereas FIG. 9c shows an embodiment with a floating flag suspended from a lower section only, such that the illumination along the upper edge of the light guide 53″ is more profound.

[0097] The different blinker modules described above provide a variety of design features which can be combined in any possible manner in order to allow a car manufacturer to individualize its rearview devices.

[0098] The features disclosed in this description, the claims and the figures may be essential for the disclosure in its different embodiments both individually and in any combination with one another.

REFERENCE SIGN LIST

[0099] 1 blinker module [0100] 3 lighting element [0101] 5 illuminant unit [0102] 7 illuminant [0103] 8 circuit board [0104] 9 end [0105] 11 end section [0106] 13 transition region [0107] 15 first surface region [0108] 17 first coating element [0109] 19 second surface region [0110] 21 second coating element [0111] 23 rearview device [0112] 25 housing [0113] 27 casing [0114] 29 casing [0115] 50, 50′, 50″, 50′″ blinker module [0116] 51 housing [0117] 53, 53′, 53″, 53′″ lighting guide [0118] 54′ texture [0119] 55, 55′ illuminant unit [0120] 56 housing recess [0121] 57′, 57″, 57′″ illuminant [0122] 58, 58′ circuit board [0123] 60, 60′, 60″, 60′″ lens [0124] 65, 65′, 65″, 65′″ insert or inner cover [0125] 66″ slot [0126] 70 rearview device [0127] 75, 75′ casing [0128] 77 casing [0129] 100 flowchart [0130] 101, 103, 105 method steps