WO2024036553A1

WO2024036553A1 - Luminous module for a motor vehicle

Info

Publication number: WO2024036553A1
Application number: PCT/CN2022/113234
Authority: WO
Inventors: Lin Chen; Lu Bai; Yves Gromfeld
Original assignee: Valeo Vision; Valeo Lighting Hubei Technical Center Co., Ltd.
Priority date: 2022-08-18
Filing date: 2022-08-18
Publication date: 2024-02-22

Abstract

A luminous module of a motor vehicle, comprises : a first light source (2) and a second light source (3); a first collector (4) has a first reflective surface (41) configured to collect and reflect light rays emitted by the first light source (2) and a second collector (5) has a second reflective surface (51) configured to collect and reflect light rays emitted by the second light source (3); an optical system configured to project light rays comes from the first collector (4) into a first light beam (LB), the optical system is configured to form an image of the first reflective surface (41) and said first reflective surface (41) is configured so that said first light beam (LB) has an upper cut-off; the optical system is also configured to project light rays comes from the second collector (5) into a second light beam (HB), the optical system is configured to form an image of the second reflective surface (51) and said second reflective surface (51) is configured so that said second light beam (HB) extends at least partially above said upper cut-off; wherein said first and second collector (4,5) are formed by a single piece, said single piece comprises an optical shield (8) extend between said first and second collectors (4,5).

Description

Luminous module for a motor vehicle

The invention relates to the field of motor vehicle lighting and signaling field. More par‐ticularly, the invention relates to a luminous module adapted to achieve at least two light‐ing or signaling function.

In the automotive lighting or signaling field, there is a recurrent need for a luminous mod‐ule that can achieve at least two luminous functions, as a low beam function and a high beam function. In other words, such module shall be able to emit at least two different light beams, from a same output surface.

It is known optical modules that answer to this need, with combining several light sources and several collectors. In these modules, an intermediate shield or folder is disposed in the optical path of light rays emitted by one of the light sources, to define an upper cut‐off in the light beam projected by the lens from these light rays. However, such a luminous module has the drawback of requiring a high precision in the positioning of the shield or the folder, to ensure that the cut‐off achieve regulation requirements of this light beam. This precision implies that the projecting lens must be a thick lens because of its small fo‐cal length, which has the effect of increasing its weight and complicating the production thereof.

The published application US2021010653 discloses such bi‐function module, comprising two light sources each associated with a collector, and combined with a projection lens configured to form luminous images of the reflective surfaces of the collectors, when the‐se surfaces are illuminated by their respectively associated light source. Although this so‐lution effectively answers to the above cited need with increasing the positioning toler‐ance of the module elements, it requires the projection lens to be specifically designed to image both reflective surfaces. Consequently, the lens of such module consists in a lens segmented in many areas, each optimized for one of the collectors. This design might have an impact on the flexibility to achieve a specific aesthetic aspect, which is a strong constraint to lens design.

Considering the above, there is therefore a need for a luminous module able to achieve at least two different luminous functions, which is tolerant regarding the positioning of its elements to each other and which can be easily designed regardless the aesthetic con‐straint required for the projection optical system.

The object of the present invention is to answer to this need.

For this purpose, the subject of the invention is a luminous module of a motor vehicle, comprising :

a. a first light source and a second light source ;

b. a first collector having a first reflective surface configured to collect and reflect light rays emitted by the first light source and a second collector having a second reflective surface configured to collect and reflect light rays emitted by the second light source;

c. an optical system configured to project light rays coming from the first collector into a first light beam, the optical system being configured to form an image of the first reflec‐tive surface and said first reflective surface being configured so that said first light beam has an upper cut‐off; the optical system being also configured to project light rays com‐ing from the second collector into a second light beam, the optical system being config‐ured to form an image of the second reflective surface and said second reflective surface being configured so that said second light beam extends at least partially above said up‐per cut‐off;

wherein said first and second collector are formed by a single piece, said single piece comprising an optical shield extending between said first and second collectors.

According to the invention, each pair of first and second light sources and first and second collectors can produce a light beam, each light beam being able to achieve, alone or in combination with a further light beam, a luminous function. Moreover, since the collec‐tors are formed on a same piece and are separated from each other by an optical shield, it might be considered, from the point of view of the optical system, as a single reflective surface segmented in two areas, each clearly dedicated to one of the luminous function. Therefore, a same optical system can be used to project these beams, without having to segment it in several areas each dedicated to one of the collectors. The optical system can be thus freely designed, in order to comply with the required aesthetic constraints.

Advantageously, each of the first and second collectors are similarly oriented regarding the first and the second light sources. In other words, each of the first and second collec‐tors defines a cavity forming the first and second reflective surfaces, the cavities being oriented in a same direction.

According to one advantageous embodiment of the invention, at least one, especially each, of the first collector and second collector is configured so that the light rays reflect‐ed by a rear portion of the reflective surface of said collector are parallel to an optical axis of the optical system or have, in a vertical plane with respect to said axis, an angle of incli‐nation smaller than or equal to 25°, and preferably an angle of inclination smaller than or equal to 10°.

According to one advantageous embodiment of the invention, at least the second light source, especially each of the first and second light sources, is configured to emit in a main direction that is perpendicular to an optical axis of the optical system or that is in‐clined with respect to a direction perpendicular to said optical axis by an angle smaller than or equal to 25°. Advantageously, the first and second reflective surfaces have an el‐liptical or parabolic profile. Preferably, it is a surface of revolution of said profile. The revo‐lution is about an axis that advantageously is parallel to an optical axis of the optical sys‐tem. According to one variant, the reflective surface is a free‐form surface or a swept sur‐face or an asymmetric surface. It may also comprise a plurality of segments.

According to one advantageous embodiment of the invention, the first reflective surface comprises a rear edge, and the optical system has a focal area located in proximity, espe‐cially at a distance lesser than 10 mm, to this rear edge, said upper cut‐off in the first light beam being defined by the rear edge of the first reflective surface. Thus, the optical shield extends rearward from the rear edge of the first reflective surface towards a front edge of the second reflective surface. According to this embodiment, the first and second reflec‐tive surfaces are offset from each other following an optical axis of the optical system, the second reflective surface being located behind the first reflective surface, considering this optical axis and the optical path of the rays reflected by the collectors. For instance, said focal area may be a focal point or a line of focal points. Advantageously, said focal line may intersect with said rear edge. These features make it possible to produce an upper cut‐off in the first light beam, while the module remains compact, particularly in height, and sim‐ple to produce.

According to one advantageous embodiment of the invention, the optical shield extends generally in a plane, especially an horizontal plane. Advantageously, the optical system has an optical axis, which is contained in said plane. Preferably, the first collector and the se‐cond collector are located on both sides of said plane and of said optical axis. For instance, the first collector may extend above the optical axis and the second collector may extend below the optical axis and the first collector. According to these features, the image of the second reflective surface of the first collector is inverted, with respect to the optical axis, versus the image of the first reflective surface. In other words, the second light beam ex‐tends, at least partially, above the upper cut‐off of the first light beam.

According to one advantageous embodiment of the invention, the rear edge has a step intended to form a part of said upper cut‐off, said step extending along the entire length of the optical shield to the front edge of the second reflective surface. For instance, the rear edge may have a globally elliptical profile, in which is formed the step, said step pro‐truding rearward from the rest of the rear edge. If so, the front edge of the second reflec‐tive surface may have a profile identical to the rear edge of the first reflective surface and may have a step. With this type of rear edge, it is possible to produce a low beam with a kinked upper cut‐off, as it might be required by some regulations. As a variant, the rear edge may have a globally continuous profile. With this type of rear edge, it is possible to produce a low beam with a flat upper cut‐off, as it might be required by other regulations.

According to one advantageous embodiment of the invention, the first and the second light sources are disposed on a same substrate and are each able to emit light rays in a same direction. This configuration helps to reduce the cost of the luminous module.

According to an other embodiment of the invention, the luminous module comprises a third collector having a third reflective surface configured to collect and reflect light rays emitted by the first light source towards the first collector. If so, the first and the second light sources may be each disposed on a dedicated substrate, the substrate of the first light source being for example oriented perpendicularly to the substrate of the second light source. In other words, the first light source may be able to emit light rays in a direc‐tion different to the direction in which the second light is able to emit light rays. This con‐figuration allows to increase the optical performance of the luminous module with in‐creasing the maximum of intensity that the first light beam is able to achieve.

Advantageously, the third reflective surface has an elliptical profile configured to focus light rays coming from a first focal point to a second focal point, the first focal point being located on the first light source and the second focal point being located on the focal area of the optical system.

According to one advantageous embodiment of the invention, the optical system is a lens with a same entrance face for the light rays of the first light beam and for the light rays of the second light beam. As a variant, the optical system may comprise one or more lens and/or one or more reflector.

According to one advantageous embodiment of the invention, the first light beam forms a portion or the entirety of a low beam function and wherein the first light beam forms a portion or the entirety of a high beam function. For instance, the upper cut‐off of the first light beam may be completely flat or may comprise a first flat portion and a second flat portion vertically offset from the first flat portion, the two flat portions being separated by an oblique portion.

The subject of the invention is also a lighting device of a motor vehicle, comprising a lumi‐nous module according to the invention.

The present invention will be better understood, and other advantages will appear on reading the detailed description of an embodiment taken by way of non‐limiting example and illustrated by the appended drawings, in which:

[Fig. 1] is a schematic representation of a luminous module according to a first embodi‐ment of the invention;

[Fig. 2] is a perspective view of the luminous module of [Fig. 1] ;

[Fig. 3] is a top view of the collectors of the luminous module of [Fig. 1] ;

[Fig. 4A] is a graphical representation of the luminous images of the first light beam pro‐duced by the luminous module of [Fig. 1] ;

[Fig. 4B] is a graphical representation of the luminous images of the second light beam produced by the luminous module of [Fig. 1] ; and

[Fig. 5] is a schematic representation of a luminous module according to a second embod‐iment of the invention.

In the following description the notions “above” and “below” are to be understood with respect to the luminous module when it is in functional position, i.e. with an orientation that corresponds to that for which it was designed. Similarly, the notions “front” and “rear” are to be understood with respect to the general direction of the light, along the optical axis of the luminous module, when the luminous module is in functional position.

[Fig. 1] to [Fig. 4B] represents a first embodiment of a luminous module 1 according to the invention.

[Fig. 1] is a schematic side view of the luminous module and of its operating principle, while [Fig. 2] is a perspective view of this module.

The luminous module 1 comprises a first light source 2 and a second light source 3, each mounted a substrate (not represented) . The

light sources

2 and 3 are advantageously semiconductor light sources, and in particular light‐emitting diodes.

Each of the

light sources

2 and 3 emits light rays in a half‐space bounded by the substrate on which said source is mounted. In the shown example, the substrate of the first light source 2 is oriented perpendicularly to the substrate of the second light source 2. Thus, the first light source 2 emits light rays rearward, in a main direction parallel to an optical axis X‐X of the luminous module, while the second light source 3 emits light rays upward, in a main direction perpendicular to the optical axis X‐X. According to the invention, the main direction of emission of the first light source 2 will possibly be inclined with respect to a direction parallel to the optical axis X‐X by an angle smaller than or equal to 25°., and the main direction of emission of the second light source 3 will possibly be inclined with respect to a direction perpendicular to the optical axis X‐X by an angle smaller than or equal to 25°.

The luminous module 1 comprises a first collector 4 able to reflect the light rays emitted by the first light source 2 in order to form a first light beam LB along the optical axis X‐X of the module 1, and a second collector 5 able to reflect the light rays emitted by the second light source 3 in order to form a second light beam HB along the optical axis X‐X. The module 1 also comprises a lens 6 for projecting said beams LB and HB. According to the invention, the lens 6 may be replaced by any other projecting optical systems, such as in particular one or more mirrors.

In order to redirect light rays emitted by the first light source 2 towards the first collector 4, the module 1 comprises a third collector 7.

The third collector 7 comprises a carrier, of shell or cap shape, and a reflective surface 71 formed on the interior face of the carrier. The shell‐or cap‐shaped collector is advanta‐geously made from materials having a good heat resistance, for example of glass or of synthetic polymers such as polycarbonate PC or polyetherimide PEI. The reflective surface 71 is advantageously made by a reflective coating applied on the carrier, such as an alu‐minum or a silver coating.

The reflective surface 71 has an elliptic profile and thus is configured to concentrate or focus light rays coming from a first focal point 72, one which the first light source 2 is lo‐cated, to a second focal point 73, located in proximity of the first collector 4. Therefore, the reflective surface 71 is configured to collect and reflect light rays emitted by the first light source 2 towards the first collector 4.

The first and

second collectors

4 and 5 are formed on a same carrier, which has two cavi‐ties defining these first and

second collectors

4 and 5, a reflective surface 41, respectively 51, being formed on the interior face of each cavity.

The reflective surfaces 41 and 51 advantageously have an elliptical or parabolic profile. At least one thereof is advantageously a surface of revolution about an axis parallel to the optical axis X‐X. Alternatively, it may be a free‐form surface or a swept surface or an asymmetric surface. It may also comprise a plurality of segments. Each of reflective sur‐faces 41 et 51 is thus configured to collect and reflect light rays emitted by the first light source 2, and reflected by the third collector 7, and by the second light source 3 towards the lens 6.

Furthermore, each of the first collector 4 and second collector 5 is configured so that the light rays reflected by a rear portion of the

reflective surface

41, 51 are parallel to the op‐tical axis X‐X or have, in a vertical plane with respect to said axis X‐X, an angle of inclina‐tion smaller than or equal to 25°, and preferably an angle of inclination smaller than or equal to 10°.

The cavities, on which the

reflective surfaces

41 and 51 are formed, are oriented in a same direction, in particular downward in the shown example. Thus, the reflective surfac‐es 41 and 51 are offset from each other following the optical axis X‐X, the second reflec‐tive surface 51 being located behind the first reflective surface 41. Moreover, the first col‐lector 4 extends above the optical axis X‐X and the second collector 5 extends below the optical axis X‐X and the first collector 4.

The first and

second collectors

4 and 5 being formed on a same and single carrier, an opti‐cal shield 8 formed on this carrier extends between said first and

second collectors

4 and 5.

The optical shield 8 extends generally in an horizontal plane, containing the optical X‐X, between a rear edge 42 of the first reflective surface 41 and a front edge 52 of the second reflective surface 51, with which the optical shield 8 joins these

reflective surfaces

41 and 51.

The lens 6 has a line of focal points 61 passing by the rear edge 42 of the first reflective surface and on which the second focal point 73 of the third collector 7 is located. Thus, the lens 6 is configured to project light rays coming from the first collector 4 into the first light beam LB, with forming an image of the first reflective surface 41. The rear edge 42 therefore defines an upper cut‐off LB1 in said image and thus in the first light beam LB1.

The lens 6 is also configured to project light rays coming from the second collector 5 into the second light beam LB, with forming an image of the second reflective surface 51. Con‐sidering the rearward position of the second collector 5, compared with the position of the first collector 4 and the location of the focal points 61 of the lens 6, the second light beam HB extends at least partially above said upper cut‐off LB1 of the first beam LB. Moreover, since the optical shield 8 extends generally in an horizontal plane, located at proximity or on the optical axis X‐X of the lens 6, both

reflective surfaces

41 and 51 form, from the points of view of the lens 6, a single reflective surface. This implies that there is no need to specifically design a dedicated area in the lens 6, namely an input face and/or an exit face, for each

collector

4 and 5. On the contrary, the lens 6 has a same input face and same exit face for the light rays of the first light beam LB and for the light rays of the second light beam HB.

In the shown example, as disclosed in [Fig. 3] , the rear edge 42 has a globally elliptical profile, in which is formed a step 43 protruding rearward from the rest of the edge. Said step 43 is intended to form a part of the upper cut‐off LB1. The [Fig. 4A] represents the projection, on a vertical screen disposed at a distance of 25m from the luminous module 1, of the first light beam LB projected by the luminous module 1 when the first light source 2 only is lit. The upper cut‐off LB1 has a first flat portion and a second flat portion, vertically offset from the first flat portion, these two flat portions being separated by an oblique portion. All these portions are formed by the rear edge 42, the oblique portion being specifically formed by the step 43. The first light beam LB can therefore form a por‐tion of a low beam function, and can be completed with an other light beam having a broader extension and a flat upper cut‐off intended to be superimposed with the lower flat portion of the upper cut‐off LB1, so as to form a full low beam function complying with European regulations.

As shown on [Fig. 3] , which represents a top view of the carrier forming the first collector 4, the second collector 5 and the optical shield 8, said step 43 extends from the rear edge 42 on the optical shield 8, along the entire length of the optical shield 8, and to the front edge 52 of the second reflective surface 5. The front edge 52 has thus a profile identical to the rear edge 42 of the first reflective surface 51, with a step 53.

The [Fig. 4B] represents the projection, on a vertical screen disposed at a distance of 25m from the luminous module 1, of the second light beam HB projected by the luminous module 1 when the second light source 3 only is lit. The second light beam HB extends upward, over the upper cut‐off LB1 of the first light beam. The second light beam HB can therefore form a portion of a high beam function, and can be completed with a low beam function, for instance formed partially with the first light beam LB, so as to form a full low beam function complying with European regulations.

[Fig. 5] represents a second embodiment of a luminous module 10 according to the inven‐tion.

The luminous module 10 is similar to the luminous module 1 of [Fig. 1] to [Fig. 4] , except that the first and the second

light sources

2, 3 are disposed on a same substrate and are each able to emit light rays in a same direction. Therefore, there is no need in this embod‐iment for a third collector intended to redirect light rays emitted by the first light source towards the first collector.

The disclosure and the illustrations are to be considered as illustrative rather than restric‐tive, and the invention extends to all combinations, modifications, enhancements and other embodiments, which fall within the true spirit and scope of the description. In light of these various embodiments and the variants thereof, it will be understood that various combinations of lighting and/or signaling light beams are possible in a given luminous de‐vice. In particular, the number of light sources and of corresponding collectors is not lim‐ited to two. Specifically, it is contemplated to provide more light sources and more corre‐sponding collectors. Furthermore, the invention is not limited to the beam shapes or the lighting functions that have been described. The rear edge may have a different profile, as such as a globally continuous profile. The luminous module might be intended to achieve segmented high beams or glare free high beams or fog light.

Claims

Luminous module of a motor vehicle, comprising:

a. a first light source and a second light source;

b. a first collector having a first reflective surface configured to collect and reflect light rays emitted by the first light source and a second collector having a second reflective surface configured to collect and reflect light rays emitted by the second light source;

c. an optical system configured to project light rays coming from the first collector into a first light beam, the optical system being configured to form an image of the first reflective surface and said first reflective surface being configured so that said first light beam has an upper cut‐off; the optical system being also configured to project light rays coming from the second collector into a second light beam, the optical system being configured to form an image of the second reflective surface and said second reflective surface being configured so that said second light beam extends at least partially above said upper cut‐off;

wherein said first and second collector are formed by a single piece, said single piece comprising an optical shield extending between said first and second collectors.
Luminous module according to claim 1, wherein the first reflective surface comprises a rear edge, wherein the optical system has a focal area located in proximity to this rear edge, said upper cut‐off in the first light beam being defined by the rear edge of the first reflective surface, and wherein the optical shield extends rearward from the rear edge of the first reflective surface towards a front edge of the second reflective surface.
Luminous module according to claim 2, wherein the optical shield extends generally in a plane.
Luminous module according to one of the claims 2 or 3, wherein the rear edge has a step intended to form a part of said upper cut‐off, said step extending along the entire length of the optical shield to the front edge of the second reflective surface
Luminous module according to one of the preceding claims, wherein the first and the second light sources are disposed on a same substrate and are each able to emit light rays in a same direction.
Luminous module according to one of the claims 1 to 5, characterized in that it comprises a third collector having a third reflective surface configured to collect and reflect light rays emitted by the first light source towards the first collector.
Luminous module according to the claim 5 when it depends to the claim 2, wherein the third reflective surface has an elliptical profile configured to focus light rays coming from a first focal point to a second focal point, the first focal point being located on the first light source and the second focal point being located on the focal area of the optical system.
Luminous module according to one of the preceding claims, wherein the optical system is a lens with a same entrance face for the light rays of the first light beam and for the light rays of the second light beam.
Luminous module according to one of the preceding claims, wherein the first light beam forms a portion or the entirety of a low beam function and wherein the first light beam forms a portion or the entirety of a high beam function.
Lighting device of a motor vehicle, comprising a luminous module according to one of the preceding claims.