TECHNICAL FIELD

[0001] The present invention relates to an aiming system for a vehicle lamp, and more particularly, to a pivot unit of an aiming system for a vehicle lamp.

BACKGROUND

[0002] In general, automotive vehicle lamps comprises a housing, which is closed by a transparent wall in which a lighting module is placed. The lighting module comprises mainly a light source unit and an optical system, which can modify at least one parameter of light. The optical system comprises optical components such as a reflector, a lens, and optionally a diffusing element or a collimator. The housing may also accommodate various other elements, such as an aiming system. With the help of the aiming system, the lighting module can be movable relative to the housing to adjust the orientation of the illuminated beam. Fig.1 shows an enlarged view of a portion of a vehicle lamp, according to prior art. The vehicle lamp further comprises a heat sink 120, which is positioned proximate to the aiming system 100 as shown in Fig.1. Further, as can be seen from Fig.1 , the aiming system 100 comprises three connection points 105, 110, 115 by means of which the orientation of the illumination beam is adjusted. Due to the limited space availability inside the vehicle lamp, it may not be possible to increase the size of the heat sink, as the aiming system is proximate to the heat sink. Further, it is not possible to arrange the aiming system at a different location inside the vehicle lamp, as the aiming system has to be positioned at a rear side of the lighting module. In addition, aiming systems of some known vehicle lamps require three screws in order to adjust the orientation of the illuminated beam.

SUMMARY OF THE INVENTION [0003] An object of the present invention is to solve the disadvantages described above. In particular, the object of the present invention is to provide an aiming system for a vehicle lamp, which can adjust the orientation of the illuminated beam by employing two aiming screws, while ensuring to provide a larger space for accommodating a heat sink inside the vehicle lamp.

[0004] Another object of the present invention is to provide a robust pivot connection for an aiming system, which can withstand vibrations.

[0005] Yet, another object of the present invention is to provide a vehicle lamp in which heat generated by light sources of a lighting module can be effectively dissipated.

[0006] According to an embodiment of the present invention, there is provided an aiming system for a vehicle lamp, the aiming system comprises: a horizontal aiming unit and a vertical aiming unit, wherein the horizontal aiming unit and the vertical aiming unit are configured to connect a support member and a housing of the vehicle lamp, and the horizontal aiming unit is configured to adjust an optical axis of a lighting module of the vehicle lamp in a vehicle width direction and the vertical aiming unit is configured to adjust the optical axis in a vehicle height direction. Further, the aiming system comprises a pivot unit configured to connect the support member and a heat sink of the vehicle lamp, wherein the pivot unit comprises a pivot stud integrally formed with the heat sink, and the pivot unit is configured to provide a rotation center to adjust the optical axis. Thus, in accordance with the claimed invention, a connection point, i.e. , the pivot stud for the pivot unit is directly formed on the heat sink unlike in known vehicle lamps. Advantageously, by providing the connection point on the heat sink, the size of the heat sink can be increased. That is to say, a larger size of the heat sink can be accommodated inside the vehicle lamp by utilizing the free space realized by moving the connection point onto the heat sink. Hence, the heat generated by light sources of the lighting module can be effectively dissipated. Advantageously, the pivot stud of the claimed invention eliminates the use of a pivot screw, which is generally employed in aiming systems of known vehicle lamps.

[0007] In a non-limiting embodiment of the present invention, the horizontal aiming unit comprises a horizontal aiming screw and a first aiming nut; and the vertical aiming unit comprises a vertical aiming screw and a second aiming nut. Further, first ends of the aiming screws are rotatably supported on a housing of the vehicle lamp and second ends opposite to the first ends are engaged and connected to a support member of the lighting module via the first aiming nut, and the second aiming nut, respectively.

[0008] In a non-limiting embodiment of the present invention, the pivot stud comprises a base portion protruding from a front face of the heat sink, and wherein the front face is configured to receive a light source support, i.e. , a Printed Circuit Board (PCB).

[0009] In a non-limiting embodiment of the present invention, the pivot stud further comprises a ball shaped portion extending from the base portion, and is configured to be coupled to the support member via a third aiming nut.

[0010] In a non-limiting embodiment of the present invention, the pivot stud and the heat sink are made of the same material. According to another embodiment of the present invention, the pivot stud and the heat sink can be made from different materials.

[0011] In a non-limiting embodiment of the present invention, the pivot stud is made of aluminium. Thus, by providing the pivot stud made of aluminium, a robust pivot connection can be achieved. That is to say, the pivot stud is free from breakages that may occur when the vehicle is subjected to vibrations. It is understood to a person skilled in the art that the pivot stud can be made from other materials, which can ensure to provide the robust pivot connection.

[0012] The present invention also relates to a lighting module for a vehicle lamp of an automotive vehicle, the lighting module comprises: a support member to support the lighting module; a heat sink; at least one light source mounted on a light source support fixed to the heat sink; and an aiming system as has just been presented.

[0013] In a non-limiting embodiment of the present invention, the at least one light source is configured to perform lighting and/or signalling functions comprising at least one of: Turn indicator (Tl) function, DRL function, stop function, position light function, and low beam.

[0014] In a non-limiting embodiment of the present invention, the heat sink is fixedly mounted in the lighting module, and the support member is movable relative to the heat sink. The heat sink on which the pivot stud is integrated is fixedly mounted inside the vehicle lamp. That is to say, the heat sink on which the pivot stud is integrated does not participate in an aiming operation, i.e., in adjusting the optical axis of the vehicle lamp.

[0015] The present invention also relates to a vehicle lamp for an automotive vehicle comprising a housing, and at least one lighting module as has just been presented.

BRIEF DESCRIPTION OF THE INVENTION

[0016] To complete the description and to provide a better understanding of the invention, a set of drawings is provided. Said drawings form an integral part of the description and illustrate an embodiment of the invention, which should not be construed as restricting the scope of the invention, but only as an example of how the invention can be carried out. The drawings comprise the following characteristics.

[0017] Fig.1 shows an enlarged view of a portion of a vehicle lamp, according to prior art.

[0018] Fig.2a shows an isometric view of a vehicle lamp, according to an embodiment of the present invention.

[0019] Fig.2b shows different components accommodated inside the vehicle lamp shown in Fig.2a, according to an embodiment of the present invention. [0020] Fig .2c shows an enlarged view of a portion of the vehicle lamp shown in the Fig.2a, according to an embodiment of the present invention.

[0021] Fig.2d shows an isometric view of a rear wall of a housing of the vehicle lamp shown in the Fig.2a, according to an embodiment of the present invention.

[0022] Fig.3 shows a support member of a lighting module of the vehicle lamp shown in Fig.2a, according to an embodiment of the present invention. [0023] Fig.4a shows a horizontal aiming screw and a first aiming nut of an aiming system of the vehicle lamp shown in Fig.2a, according to an embodiment of the present invention.

[0024] Fig.4b shows a vertical aiming screw and a second aiming nut of an aiming system of the vehicle lamp shown in Fig.2a, according to an embodiment of the present invention.

[0025] Fig.5a shows an isometric view of a heat sink of the vehicle lamp shown in Fig.2a, according to an embodiment of the present invention.

[0026] Fig.5b shows a third aiming nut of a pivot unit of an aiming system of the vehicle lamp shown in Fig.2a, according to an embodiment of the present invention.

[0027] Fig. 6 shows a sectional view of the heatsink of the vehicle lamp shown in the Fig.5a, according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0028] Embodiments of the present application will below be explained in details by ways of examples with reference to the accompanied drawings. Throughout the description, same or similar reference numerals represent same or similar parts. The following description of the embodiments with reference to the drawings is intended to explain the general inventive concept of the present application, instead of limiting it to the present invention.

[0029] In the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. It will be apparent, however, that one or more embodiments may be practiced without these specific details.

[0030] The terminology used herein is for the purpose of describing embodiments and is not intended to be limiting and/or restrictive of the disclosure.

[0031] It should be noted that the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0032] Also, it will be understood that, although the terms first, second, etc. may be used herein to describe various elements, the elements are not limited by these terms. These terms are only used to distinguish one element from another.

[0033] The term “optical axis” is used herein to refer to an imaginary line or plane that defines a path along or proximate which light propagates.

[0034] The term "vehicle width direction" is used herein to refer to a width direction of a vehicle and corresponds to a left-right direction of the vehicle body.

[0035] The term “vehicle height direction" is used herein to refer to a height direction of a vehicle and corresponds to an up-down direction of the vehicle body.

[0036] The present invention applies preferably to motor vehicle lighting devices. In particular, a motor vehicle lighting device can be a lighting and/or signalling device. As an example, the lighting device can be a front lamp (headlamp) or a rear lamp of a motor vehicle. More specifically, the lighting device may include, without limitation, one or more of the following: a main beam module, a dipped beam module, a daytime running lamp, a lantern, a turn signal lamp, a stop lamp, a position lamp, a direction indicator, and a fog lamp.

[0037] Fig.2a shows an isometric view of a vehicle lamp, according to an embodiment of the present invention. Fig.2b shows different components accommodated inside vehicle lamp shown in Fig.2a. Fig.2c shows an enlarged view of a portion of the vehicle lamp shown in the Fig.2a. Fig.2d shows an isometric view of a rear wall of a housing of the vehicle lamp shown in the Fig.2a.

[0038] According to an embodiment of the present invention, the vehicle lamp 200 shown in the Fig.2a comprises a housing 210, which is closed by a transparent outer lens 205. A lighting module 215 (shown in Fig.2b), which irradiates the area in front of the vehicle with light, is received in the housing 210. The vehicle lamp 200 further includes a support member 220 for supporting the lighting module 215. The lighting module 215 and the support member 220 are clearly shown in Fig.2b. The support member 220 is configured to serve as a swivelling center of the lighting module 215 in vertical and horizontal directions. For instance, the support member 220 is a bracket of the lighting module 215. The lighting module 215 may be fixed to the support member 220 by means of a mounting part (not shown in Figures) of the lighting module 215. Although a single lighting module is shown in the Fig.2b and Fig.2c, it is understood to a person skilled in the art that the vehicle lamp 200 can include a plurality of lighting modules for performing different types of lighting and/or signalling functions.

[0039] The lighting module 215 comprises at least one light source (not shown in the Figures) associated with an optical system (not shown in the Figures), and configured to emit one or more light beams along an optical axis of the lighting module 215. The light source is any device able to emit light, such as a filament bulb, a gas-discharge bulb or also a device combining one or more light-emitting semi-conductor light sources, or one or more light-emitting diodes (LEDs). The optical system can modify at least one parameter of the light generated by the light source in order to emit the light beam by the lighting module. The optical system comprises optical components such as a reflector, lens, diffuser, collimator or any other device (not shown in the Figures) that can modify at least one of the parameters of the light generated by the light source, such as its average reflection and/or its direction, or even a combination of a plurality of these elements (not shown in the Figures).

[0040] The vehicle lamp 200 further comprises a heat sink 225 (shown in Fig.2b and Fig.2c) for dissipating heat generated when the at least one light source is driven, that is, when light is emitted from the at least one light source. The at least one light source is configured to perform lighting and/or signalling functions comprising at least one of: Turn indicator (Tl) function, Daylight Running Lamp (DRL) function, position light function, stop function, and low beam. In one variant of the invention, the at least one light source is configured to perform one or more signalling functions, for example, Tl function, DRL function, position light function etc. According to another variant of the invention, the at least one light source is configured to perform one or more signalling functions and a low beam function.

[0041] Referring now to Fig.2c, the vehicle lamp 200 further provided with an optical axis displacement unit or an aiming system 230 configured to displace or adjust the optical axis of the lighting module 215, i.e. , to adjust the orientation of the illuminated beam emerging out from the lighting module 215. According to a variant of the present invention, the aiming system 230 may be operated manually to adjust the optical axis of the lighting module 215. For example, by using a tool such as a wrench or the like, the aiming system may be operated manually to adjust the optical axis. According to another variant of the present invention, the aiming operation by the aiming system 230 may be performed automatically to adjust the optical axis of the lighting module 215. For instance, a tilt angle of a vehicle axle (longitudinal axle) with respect to the road surface is measured by a tilt sensor, and an Electronic Control Unit (ECU) controls the driving of a levelling actuator to adjust the optical axis based on the measured tilt angle. Techniques to perform the automatic adjustment of the optical axis are well known to a person skilled in the art.

[0042] The aiming system 230 comprises a horizontal aiming unit 235, a vertical aiming unit 240 and a pivot unit 245, as shown in the Fig.2c. The horizontal aiming unit 235 and the vertical aiming unit 240 are configured to connect the support member 220 and the housing 210, in particular, a rear wall of the housing 205. The horizontal aiming unit 235 is configured to adjust the optical axis of the lighting module 215 in a vehicle width direction and the vertical aiming unit 240 is configured to adjust the optical axis of the lighting module 215 in a vehicle height direction. Further, the pivot unit 245 is configured to connect the support member 215 and the heat sink 225, and the pivot unit 245 is configured to provide a rotation center to adjust the optical axis. In an aspect, the horizontal aiming unit 235 is positioned away from the pivot unit 245 in horizontal direction and the vertical aiming unit 240 is positioned away from the pivot unit 245 in vertical direction, as shown in the Fig.2c. In other words, the horizontal aiming unit 235 is horizontally aligned with the pivot unit 245, and the vertical aiming unit 240 is vertically aligned with the pivot unit 245. That is to say, the horizontal aiming unit 235, the vertical aiming unit 240, and the pivot unit 245 are positioned in such a way that they form a triangle. Further, the horizontal aiming unit 235, the vertical aiming unit 240, and the pivot unit 245 are arranged on a rear side of the lighting module 215.

[0043] Referring now to Fig.3, the structure of the support member 220 will be described in detail. As mentioned above, the support member 220 is pivotally connected to the housing 210 by means of the horizontal aiming unit 235 and the vertical aiming unit 240 in such a manner that the support member 215 is tiltable in the right-and-left direction and in up-and-down direction, i.e. , in the vehicle width direction and the vehicle height direction, respectively, relative to the housing 210. In other words, a tiltable member, i.e., the support member 220 is assembled to a stationary member, i.e., the housing 205 by means of the horizontal aiming unit 235 and the vertical aiming unit 240. The support member 220 shown in the Fig.3 comprises three connection points, namely, a first connection point 220a, a second connection point 220b and a third connection point 220c. As can be seen from the Fig.3, these three connection points form a triangle. For instance, these three connection points 220a, 220b, 220c may be insertion holes or cavities formed on a rear side of the support member 220.

[0044] According to an embodiment of the present invention, the horizontal aiming unit 235 shown in the Fig.2c comprises at least a horizontal aiming screw 250a and a first aiming nut 250b as shown in Fig.4a. Further, the vertical aiming unit 240 shown in the Fig.2c comprises at least a vertical aiming screw 255a and a second aiming nut 255b as shown in Fig.4b. First ends 250c, 255c of the horizontal aiming screw 250a and the vertical aiming screw 255a are rotatably supported on the housing 210. For instance, the rear wall of the housing 210 includes two plastic mating parts (not shown in the Figures), which may be configured to receive and engage the first ends 250c, 255c of the horizontal and vertical aiming screws 250a, 255a, respectively. For example, rotational operation portions (not shown in the Figures) may be integrally formed on the first ends of 250c, 255c of the horizontal and vertical aiming screws 250a, 255a, respectively. These rotational operation portions may be used for rotation operation of the aiming screws 250a, 255a to adjust the optical axis. Further, second ends 250d, 255d, which are opposite to the first ends 250c, 255c of the aiming screws 250a, 255a are engaged and connected to the support member 220 via the first aiming nut 250b, and the second aiming nut 255b, respectively. In particular, the second end 250d of the horizontal aiming screw 250a is inserted into the first connection point 220a of the support member 220 and engaged therein, and the second end 255d of the vertical aiming screw 250a is inserted into the second connection point 220b of the support member 220 and engaged therein. Thus, the vertical and horizontal aiming units 240, 235 are mounted between the housing 210 and the support member 220.

[0045] Fig.5a shows an isometric view of the heat sink of the vehicle lamp. According to an embodiment of the present invention, the pivot unit 245 shown in Fig.2c comprises a pivot stud 260, which is formed integrally with the heat sink 225. The housing 210 is provided with an opening (not shown in the Figures), in particular, an opening is provided on the rear wall of the housing. The heat sink 225 is fitted and attached to the opening, for example, via a sealing member 265. For example, the sealing member 265 is a gasket . The heat sink 225 comprises a base plate 270 that is arranged to close up the opening from inside of the housing 210, and a plurality of radiating fins 275 that protrude from a rear face 280 of the base plate 270 into the space outside the housing 210. Further, a front face 285, which is opposite to the rear face 280, is configured to receive a light source support 290, for example, a printed circuit board. As can be seen from the Fig.5a, the pivot stud 260 is integrally formed with the heat sink 225. In particular, the pivot stud 260 protrudes from the front face 285 of the heat sink 225. Although the Fig.5a shows that the pivot stud 260 protrudes from a edge of the front face 285 of the heat sink 225, it is understood to a person skilled in the art that the pivot stud 260 can be formed anywhere on the front face 285 of the heat sink 225.

[0046] As can be seen from the Fig.5a, the pivot stud 260 comprises a base portion 260a and a ball shaped portion 260b extending from the base portion 260a. For example, the base portion 260a has a cylindrical shape. The ball shaped portion 260b is configured to be coupled to the support member 220 using a third aiming nut 260c, which is shown in the Fig.5b. In particular, the ball shaped portion 260b is configured to be inserted into the third connection point 220c of the support member 220 via the third aiming nut 260c, and engaged therein. Thereby, a more reliable mechanical connection can be achieved between the pivot stud and the third connection point 220c. By providing the pivot stud 260 integrally with the heat sink 225, a free space can be realized inside the vehicle lamp 200. The free space can be utilized to increase the size of the heat sink 225, and thereby the heat generated by the at least one light source of the lighting module 215 can be effectively dissipated. Further, the pivot stud 160 of the present embodiment eliminates the use of a third aiming screw, which is generally used in aiming systems of known vehicle lamps. [0047] Fig. 6 shows a sectional view of the heatsink of the vehicle lamp shown in the Fig.5a, according to an embodiment of the present invention. As can be seen from the figure, the heatsink 225 comprises the light source support 290, and the pivot stud 260. The light source support 290 such as the Printed Circuit Board (PCB) maybe disposed on top of the heat sink 225 such that heat generated by electrical components disposed on top of the PCB is dissipated by the heat sink 225. The PCB 290 may be secured with the heat sink 225 by a conventional screw as shown in the figure. Further, the pivot stud 260 with the base portion 260a and the ball shaped portion 260b are formed integrally with the heat sink 225. In an embodiment, heat from the PCB 290 may also be dissipated by the pivot stud 260 when the pivot stud 260 and the heat sink 225 are made from the same material. As can be seen from the figure 6, the pivot stud 260 protrudes from the heat sink 225. Particularly, the base portion 206a of the pivot stud 260 is formed integrally from the heat sink 225. Therefore, in an embodiment, heat from the PCB 290 maybe transferred to the heat sink 225 and subsequently to the base portion 260a of the pivot stud 260 by conduction. Thus, better heat dissipation is achieved. Additionally, the heat dissipating portion of the heat sink 225 may be increased by the ball shaped portion 260b of the pivot stud 260. Therefore, in addition to aiding the aiming mechanism, the pivot stud 260 may also perform heat dissipation due to increased heat dissipative area thereby minimizing overheating issues in the vehicle lamp.

[0048] In an embodiment, the heat sink 225 and the pivot stud 260 are made of same material. In another embodiment, the heat sink 225 and the pivot stud 260 are made of different materials. In an aspect, the pivot stud 260 is made of aluminium. By making the pivot stud 260 using materials like aluminium, the strength of a pivot connection can be enhanced. That is to say, the pivot stud 260 is free from breakages that may occur, for example, when the vehicle is subjected to vibrations.

[0049] During the operation, the aiming system 230 allows to adjust the optical axis. As discussed previously, by using the horizontal aiming unit 235, the optical axis can be adjusted in the vehicle width direction. In particular, by rotation operation of the horizontal aiming screw 250a, the optical axis can be adjusted in the vehicle width direction. Likewise, by rotation operation of the vertical aiming screw 250b, the optical axis can be adjusted in the vehicle height direction. The horizontal and vertical aiming screws 250a and 250B are adapted to move in forward and backward in the axial direction in order to tilt the support member 220 in the vehicle width direction or in the vehicle height direction, thereby adjusting the optical axis. Hence, the aiming system 230 of the illustrated embodiment can adjust the orientation of the illuminated beam by employing only two aiming screws. Further, by moving the pivot connection onto the heat sink, an additional space can be realized inside the vehicle lamp and this additional space can be used to accommodate the heat sink of larger size.

[0050] The person skilled in the art realizes that the present invention by no means is limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims. In addition, the skilled person readily realizes that the different embodiments described herein may be combined freely to obtain new combinations.

[0051] Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantages.

LIST OF REFERENCE SIGNS

200 Vehicle lamp

205 Transparent outer lens Housing Lighting module Support member a First connection point b Second connection pointc Third connection point Heat sink Aiming system Horizontal aiming unit Vertical aiming unit Pivot unit a Horizontal aiming screwb First aiming nut c First end d Second end a Vertical aiming screw b Second aiming nut c First end d Second end Pivot stud a Base portion b Ball shaped portion c Third aiming nut Gasket Base plate Radiating fins Rear face of the base plate Front face of the base plate Light source support