阅读说明：本技术 用于改变机动车辆的前照灯光束分布的光学元件 (Optical element for changing the beam profile of a motor vehicle headlight ) 是由 H·库卢 安德森·诺罗尼亚 于 2019-07-05 设计创作，主要内容包括：本发明涉及一种光学元件(1),其包括树脂体(2),其具有覆盖有能够反射光束的反射涂层的功能表面(3),所述反射涂层包括至少部分覆盖所述功能表面(3)的铜层,覆盖铜层的镍层和覆盖镍层的铬层。(The invention relates to an optical element (1) comprising a resin body (2) having a functional surface (3) covered with a reflective coating capable of reflecting a light beam, said reflective coating comprising a copper layer covering at least partially said functional surface (3), a nickel layer covering the copper layer and a chromium layer covering the nickel layer.)

1. An optical element for modifying the beam profile of a motor vehicle headlamp, characterized in that it comprises a resin body (2) having a functional surface (3), the functional surface (3) of the resin body being covered with a reflective coating (4) capable of reflecting a beam, the reflective coating (4) comprising:

-a copper layer (5) at least partially covering the functional surface (3),

-a nickel layer (6) covering the copper layer (5), and

-a chromium layer (7) covering the nickel layer (6).

2. Optical element according to claim 1, characterized in that it further comprises a nickel plating layer (8) between the functional surface (3) and the copper layer (5).

3. Optical element according to claim 1, characterized in that it further comprises a plating layer (8), said plating layer (8) comprising a mixture of nickel and copper between said functional surface (3) and said copper layer (5).

4. Optical element according to any one of claims 1 to 3, characterized in that the nickel layer (6) comprises:

-a semi-bright nickel base layer (9) covering the copper layer (5),

-a high-sulfur nickel base layer (10) covering the semi-bright nickel base layer (9),

-a bright nickel bottom layer (11) covering the high-sulfur nickel bottom layer (10),

-a matte nickel base layer (12) covering the bright nickel base layer (11).

5. Optical element according to any one of claims 1 to 4, characterized in that the functional surface (3) has a semi-elliptical shape.

6. An optical element according to any one of claims 1 to 4, characterised in that the functional surface (3) has a planar shape.

7. A motor vehicle headlamp comprising at least one reflector (14) and at least one light source (15) capable of emitting at least one light beam, said reflector (14) having the shape of a portion of a semi-ellipsoid extending above a plane of symmetry (16) of the ellipsoid, said light source (15) being located on the axis of symmetry of the ellipsoid, characterized in that it further comprises an optical element (1) according to any one of claims 1 to 6, said optical element (1) being designed to be movable so as to vary the distribution of the light beam (18) emitted by said light source (15) and reflected by said reflector (14).

8. A headlamp according to claim 7, characterized in that the light source (15) is arranged substantially at a first focus of the ellipsoid, the reflector (14) being capable of reflecting one or more light beams towards a second focus of the ellipsoid, the functional surface (3) of the optical element (1) being arranged at the second focus.

9. Headlamp according to any of claims 7 or 8, characterized in that it comprises a drive module (16) configured to change the position of the optical element (1) between at least a first position of the optical element (1) and a second position of the optical element (1), wherein the first position of the optical element (1) is such as to form a light beam in the form of a low beam at the output of the headlamp (13) and the second position of the optical element (1) is such as to form a light beam in the form of a high beam at the output of the headlamp (13).

10. A method of manufacturing an optical element (1) for modifying a beam profile according to any one of claims 1 to 6, characterized in that it comprises the steps of:

-a step of forming a resin body (2) having a functional surface (3);

-a first step of covering at least a portion of the functional surface (3) with a copper layer (5);

-a second step of covering the copper layer (5) with a nickel layer (6);

-a third step of covering the nickel layer (6) with a chromium layer (7).

11. The method according to claim 10, characterized in that it further comprises a step of applying a nickel plating (8) before the first covering step.

12. A method according to claim 10, characterized in that the method comprises a step of covering with a plating layer (8) comprising a mixture of nickel and copper before the first covering step.

13. The method according to any one of claims 10 to 12, wherein the second covering step comprises:

-a first sub-step of applying a semi-bright nickel base layer (9) to the copper layer (5),

-a second sub-step of applying a high-sulfur nickel base layer (10) to the semi-bright nickel base layer (9),

-a third sub-step of applying a bright nickel base layer (11) on the high-sulfur nickel base layer (10), and

and a fourth substep of coating a matte nickel sublayer (12) on the bright nickel base layer (11).

[ technical field ] A method for producing a semiconductor device

The present invention relates to the field of devices for motor vehicles, and in particular to headlamps for these motor vehicles.

[ background of the invention ]

Motor vehicle headlamps generally comprise an elliptical reflector in which a light source is arranged, an optical lens allowing to block the cut-off band of the various phases of the light beam and to scatter the light beam generated on the road.

The stop band is electrically actuated by an actuator so as to move on command between at least two angular positions in which the light beam is more or less obstructed. This makes it possible to limit the range of the headlights, for example, to the range of the low beam headlights, i.e. the low beam position, in order to avoid dazzling the driver driving in the opposite direction, or to the range of the high beam headlights, i.e. the so-called high beam position, which has no obstructions. This technique is generally used for headlamps comprising high-power light sources, such as halogen or xenon headlamps, the loss of luminous intensity due to the interception of the luminous flux by the cut-off band not being really detrimental.

Currently, motor vehicle headlamp technology tends to use Light sources consisting of Light Emitting Diodes called LEDs ("Light-Emitting Diodes") due to their reduced cost and longer life. On the other hand, the luminous intensity emitted by these devices is currently still limited, and it is therefore necessary to make the best use of it. It is therefore desirable to be able to dispense with a screening member which absorbs substantially half the emitted light flux in the low beam position.

Document FR 3028002 proposes the use of a moving reflective surface. Due to its movability, the reflecting surface makes it possible to redirect the light beam as desired to form a high beam or a low beam without any obstruction, so that no part of the output of the emitted light beam is lost.

However, the reflective surface is exposed to external radiation, in particular solar radiation. Thus, heating can be achieved by focusing external radiation on the reflective surface. The reflective surface is carried by a plastic support, which is thus damaged by the heating on the reflective surface.

[ summary of the invention ]

The object of the present invention is to overcome these above drawbacks by providing a heat-resistant optical element.

To this end, the invention relates to an optical element for modifying the beam profile of a motor vehicle headlight.

According to the present invention, an optical element includes a resin body whose functional surface is covered with a reflective coating capable of reflecting a light beam, the reflective coating including:

-a copper layer at least partially covering the functional surface,

-a nickel layer covering the copper layer,

-a chromium layer covering the nickel layer.

Thus, the heat occurring on the functional surface can be dissipated by the copper layer. According to one embodiment, the optical element further comprises a nickel plating layer between the functional surface and the copper layer. According to one embodiment, the optical element comprises a plated layer comprising a mixture of nickel and copper between the functional surface and the copper layer.

The plating allows good adhesion of the reflective coating to the resin body.

According to another embodiment, the nickel layer comprises:

a semi-bright nickel base layer covering the copper layer,

a high-sulfur nickel base coat covering the semi-bright nickel base coat,

a bright nickel base coat covering the high-sulfur nickel base coat,

a matte nickel underlayer covering the bright nickel underlayer.

According to a first embodiment, the functional surface has a semi-elliptical shape.

According to the second embodiment, the functional surface has a planar shape.

The invention also relates to a motor vehicle headlamp comprising at least one reflector having the shape of a portion of a semi-ellipsoid extending above a plane of symmetry of the ellipsoid and at least one light source capable of emitting at least one light beam, the light source being located on the axis of symmetry of the ellipsoid.

According to the invention, the headlight further comprises an optical element as described above, which is designed to be movable in order to change the distribution of the light beam emitted by the light source and reflected by the reflector.

Furthermore, the light source is arranged substantially at a first focus of the ellipsoid, the reflector is capable of reflecting the light beam to a second focus of the ellipsoid, and the functional surface of the optical element is arranged at the second focus.

Furthermore, the headlamp comprises a drive module configured to change the position of the optical element between at least a first position of the optical element, which makes it possible to form a light beam in the form of a low beam at the output of the headlamp, and a second position of the optical element, which makes it possible to form a light beam in the form of a high beam at the output of the headlamp.

The invention also relates to a method of manufacturing an optical element for changing the beam profile as described above.

According to the invention, the method comprises the following steps:

-a step of forming a resin body having a functional surface;

-a first step of covering at least a portion of the functional surface with a copper layer;

-a second step of covering the copper layer with a nickel layer;

-a third step of covering the nickel layer with a chromium layer.

According to one embodiment, the method further comprises the step of applying a nickel plating layer prior to the first covering step.

According to one variant, the method also comprises a step of covering with a plating layer comprising a mixture of nickel and copper before the first covering step.

According to another embodiment, the second covering step comprises:

-a first sub-step of applying a semi-bright nickel base layer to the copper layer;

-a second sub-step of applying a high-sulfur nickel base layer to a semi-bright nickel base layer;

-a third sub-step of applying a bright nickel base coat onto the high-sulfur nickel base coat;

-a fourth sub-step of applying a matte nickel base layer to a bright nickel base layer.

[ description of the drawings ]

The invention and its features and advantages will be more clearly apparent from a reading of the description with reference to the accompanying drawings, in which:

figure 1 is a profile view of a headlamp for a motor vehicle according to one embodiment,

figure 2 is a perspective view of an optical element according to one embodiment,

figure 3 shows a cross-section of a reflective coating on a body according to an embodiment,

figure 4 shows a cross-section of a reflective coating on a body according to another embodiment.

[ detailed description ] embodiments

Fig. 1 shows a headlight 13 for a motor vehicle.

The headlight comprises at least one reflector 14 and at least one light source 15 capable of emitting at least one light beam 17.

In the following description, the term "light beam" will be used in the singular. However, it should be understood that the term may also refer to a complex form of the "beam".

The reflector 14 has the shape of a portion of a semi-ellipsoid extending above the plane of symmetry 16 of the ellipse. The light source 15 is located on the axis of symmetry of the ellipsoid. The light source may comprise at least one LED diode emitting in a solid angle of 2 pi spherical radians such that all light beams emitted by the light source are reflected by the reflector.

The headlamp 13 further comprises a movable optical element 1, which movable optical element 1 is used to change the distribution of the light beam 18 emitted by the light source 15 and reflected by the reflector 14.

Advantageously, the light source 15 is arranged substantially at the first focus of the ellipsoid. The reflector 14 can then reflect the light beam 17 towards the second focus of the ellipsoid.

The headlamp may further comprise a lens 18, the lens 18 being arranged in the path of the light beam 17 after said light beam 17 has been reflected on the reflector 14 and then blocked and/or reflected by the optical element 1. The lens 18 is preferably convergent.

Advantageously, the headlamp 13 comprises a drive module 16, the drive module 16 being configured to change the position of the optical element 1 between at least a first position of the optical element 1 and a second position of the optical element 1. The first position of the optical element 1 makes it possible to form a light beam in the form of a low beam at the output of the headlamp 13. The second position of the optical element 1 makes it possible to form a light beam in the form of a high beam at the output of the headlamp 13.

Fig. 2 shows an optical element 1 for changing the beam profile.

The optical element 1 includes a resin body 2 having a functional surface 3, the functional surface 3 of the resin body being covered with a reflective coating 4 capable of reflecting a light beam.

In a non-limiting manner, the resin may be polyphthalamide (PPA) reinforced with glass fibers (PPA GF 25-40%). The resin has excellent thermal properties and high mechanical strength. It is also antifatigue.

Preferably, the resin may be reinforced PPA (PPA MR 30%). The resin has excellent thermal properties, good mechanical strength and very good dimensional stability. PPA MR 30% is preferred for its dimensional stability. After all, a continuous coating tends to magnify any imperfections in appearance.

Advantageously, the functional surface 3 of the optical element 1 is arranged substantially at the second focal point of the ellipse.

The functional surface 3 may have a semi-elliptical or planar shape.

The semi-elliptical shape of the functional surface 3 may correspond to a concave semi-elliptical shape located outside the focal plane of the ellipsoid, between the lens 18 and the focal plane, allowing reflection of the light source 15 to achieve additional, soft light distribution over the low beam to increase visibility of the vertical traffic sign.

The reflective coating 4 comprises (fig. 3):

a copper layer 5 at least partially covering the functional surface 3,

a nickel layer 6 covering the copper layer 5, and

a chromium layer 7 covering the nickel layer 6.

The copper layer 5 corresponds to the heat conductive layer. The copper layer 5 dissipates heat generated by external radiation 19 on the functional surface 3. It also has good resistance to high temperatures and temperature variability. Copper exhibits good adhesion to the material of the resin body 2 and the nickel layer 6. The copper layer 5 also gives the reflective coating 4 good elasticity.

If the headlight 13 comprises a converging lens 18, the heat of the functional surface 3 due to the convergence of the external radiation 19 on said functional surface 3 can be dissipated through the copper layer 5. Therefore, the heating is not limited to the position where the external radiation 19 converges. This prevents the resin body 2 from being damaged.

The thickness of the copper layer 5 is, in a non-limiting manner, between 15 μm and 25 μm, preferably 20 μm.

The nickel layer 6 makes it possible to resist corrosion of the reflective coating 4. It also exhibits good weatherability.

The chromium layer 7 makes it possible to impart hardness and brightness to the reflective coating 4.

The thickness of the chromium layer is, in a non-limiting manner, between 0.1 μm and 1 μm, preferably 0.25 μm.

According to one embodiment, the reflective coating further comprises a plating layer 8 between the functional surface 3 and the copper layer 5.

The plating layer 8 may be made of nickel or include a mixture of nickel and copper.

In a non-limiting manner, the plating layer comprises 50% to 70% copper and 50% to 30% nickel. Preferably, the plating layer comprises about 60% copper and 40% nickel.

The plating layer 8 improves the adhesion of the copper layer 5 to the resin body 2.

The thickness of the coating is, in a non-limiting manner, between 0.5 μm and 1.5. mu.m, preferably 1 μm.

According to another embodiment (fig. 4), the nickel layer 6 comprises:

a semi-bright nickel underlayer 9 covering the copper layer 5,

a high-sulfur nickel base layer 10 covering the semi-bright nickel base layer 9,

a bright nickel base layer 11 covering the high-sulfur nickel base layer 10,

a matte nickel underlayer 12 covering the bright nickel underlayer 11.

The semi-bright nickel underlayer 9 provides good mutual adhesion of the copper layer 5 and the nickel layer 6. It also provides good corrosion resistance to the reflective coating 4.

The semi-bright nickel base layer 9 has a low sulfur content of 0.002 to 0.005% by mass in a non-limiting manner.

The thickness of the semi-bright nickel base layer 9 is, in a non-limiting manner, between 10 μm and 20 μm, preferably 15 μm.

The high-sulfur nickel base coat 10 provides good adhesion of the semi-bright nickel base coat 9 and the bright nickel base coat 11.

The high-sulfur nickel base layer 10 has a sulfur content of 0.1 to 0.25% by mass in a non-limiting manner. The term "high sulfur nickel" means that the nickel contains a sulfur content of 0.1 to 0.25% by mass.

The high-sulfur nickel underlayer 10 has a thickness of between 1.5 μm and 2.5 μm, in a non-limiting manner.

The bright nickel base layer 11 gives the reflective coating 4 a good gloss and improves the hardness of the reflective coating 4.

The thickness of the bright nickel base layer 11 is, in a non-limiting manner, between 5 μm and 15 μm, preferably 10 μm.

The matte nickel underlayer 12 gives the reflective coating 4 the same glossy surface as a mirror.

In a non-limiting manner, the matte nickel underlayer 12 has a thickness of 5 μm to 15 μm, preferably 10 μm.

The terms "semi-bright", "bright" and "matte" can be correlated by the relationship between diffuse and specular reflection (reflectance). Reflection can be considered diffuse if the incident ray is reflected in many directions, and specular when the incident ray is reflected in one direction.

Thus, the term "matte" may mean that diffuse reflection is greater than specular reflection. Therefore, the light energy reflected by scattering is greater than the light energy reflected by specular.

The term "bright" may mean that specular reflection is greater than diffuse reflection. Thus, the light energy reflected by specular reflection is greater than the light energy reflected by diffuse reflection.

The term "semi-bright" derives from these definitions. Thus, this may mean that the specular reflection is approximately as large as or significantly less than the diffuse reflection. Thus, the light energy reflected by specular reflection is substantially equal to or significantly less than the light energy reflected by diffuse reflection.

In a non-limiting manner, the reflectance (specular reflection) of a shiny surface is between 50% and 100%, that of a semi-shiny surface is between 20% and 50%, and that of a matte surface is less than 20%.

The optical element 1 may be manufactured by a manufacturing process comprising the steps of:

a step of forming a resin body 2 having a functional surface 3;

a first step of covering at least a portion of the functional surface 3 with a copper layer 5;

-a second step of covering the copper layer 5 with a nickel layer 6;

a third step of covering the nickel layer 6 with a chromium layer 7.

The step of forming the resin body 2 may be performed by molding the resin or by 3D printing.

The first covering step may be performed by electroless copper plating.

The second covering step may be performed by electrolytic deposition.

The third covering step may be performed by electrolytic deposition.

According to one embodiment, the method further comprises the step of applying a plating layer 8 of nickel or a mixture of nickel and copper before the first covering step.

The step of applying the plating layer 8 may be performed by electrolytic deposition.

According to another embodiment, the second covering step comprises:

a first sub-step of applying a semi-bright nickel base layer 9 to the copper layer 5;

a second sub-step of applying a high-sulfur nickel base layer 10 onto the semi-bright nickel base layer 9;

a third sub-step of applying a bright nickel base layer 11 to the high-sulfur nickel base layer 10;

a fourth sub-step of applying a matte nickel underlayer 12 onto the bright nickel underlayer 11.

Each substep may be carried out by electrodeposition.

The first capping substep may include depositing a matte nickel layer and polishing the matte nickel layer.

The third capping substep may include depositing a matte nickel layer and immersing the matte nickel layer in a bath containing a brightening additive.

The present specification describes various embodiments in detail with reference to the drawings and/or technical features. Those skilled in the art will appreciate that various features of the various embodiments can be combined with each other to arrive at other embodiments, unless explicitly stated otherwise or unless such features are incompatible.