[0001]. Field of the invention

[0002]. The present invention relates to modular light source assemblies.

[0003]. In particular, the present invention relates to modular light source assemblies, as well as to vehicle light devices.

[0004]. Background art

[0005]. With the recent advances in semiconductor light sources, such as high-performance light-emitting diodes (LEDs), there has been a growing interest in using them for manufacturing automotive lighting systems, such as headlights, indicator lights, fog lights, and signal lights. Such semiconductor light elements can offer a variety of advantages over traditional incandescent and gas- discharge light sources, including much smaller volumes, which result in a wider range of possible designs and styles, as well as potentially longer service life and reliability.

[0006]. However, the light elements which use semiconductor sources also suffer from certain disadvantages, including lower light output levels than gas discharge (Xenon) light sources and sensitivity to semiconductor light source overheating which can cause light source failures.

[0007]. This drawback implies the thermal coupling of the semiconductor source with radiators the size of which is much greater than the light source itself.

[0008]. This dimension of the light source, lens, and radiator reguires the construction of support structures which either limit the morphology of the vehicle light device or impose a complete redesign of the vehicle light device for each vehicle. In other words, miniaturization is sought, which however has to address physical limitations as well as a redesign cost that recurs for each new design.

[0009]. FR 2 855 866 describes a vehicle light device or headlamp having at least one light-terminating body fixed to a support being rotatable about an axis and/or displaceable on at least one plane with respect to the lens to adjust for thermal expansion or deformation caused by stresses created in the device.

[0010]. The headlamp comprises a light source and a collimator which focuses the light emitted from the light source onto a light coupling surface of a light guide which is divided into two light guide wires.

[0011]. Document US 2004/0149998 Al describes a lighting system comprising a plurality of radiation-generating sources, such as LED dies.

[0012]. An array of LED dies is placed in optical alignment with an array of optical elements, which can include a plurality of passive optical elements, such as focusing lenses or concentrating optical elements. Each LED die is individually mounted on a substrate and has independent electrical connections for operational control. [0013]. Each light-conducting wire leads to a light-terminating body, each of which is closely connected to a lens.

[0014]. JP 2000-149608 A describes a device comprising an LED element with a light-emitting surface embedded in a transparent body, the light emitted therefrom is introduced into an optical fiber and delivered to the opposite end for lighting.

[0015]. An LED of the constriction type, which emits light from about a point on the light-emitting surface, is used as the LED element. A fiber insertion hole is provided in the transparent body for inserting the collimator so that the focal point of the collimator is centered exactly on the light source.

[0016]. Other known modular light sources are known from EP3593033, EP3330599, EP3153770, EP2956335, DE102013217597, CN104019427, US8444298, FR2919915, EP1954981, EP1859196, US7114837, US10001253, EP2872822, EP2750929, EP1935715, EP1770328, JP2007005182, WO2016203945.

For example, solutions which arrange multiple light sources side-by- side in an adjustable and non-adjustable manner are known.

For example, document DE102006020961A1 discloses an assembly with light sources which are movable with respect to a lens. This solution allows changing the light beam but does not allow changing the arrangement of each individual light source with respect to adjacent light sources while leaving the light beam produced by the relationship between the light source and the facing lens thereof unchanged. Furthermore, this solution relates to a plurality of light sources adjusted always synchronously about a horizontal axis. For example, document DE202013100903U1 discloses telescopically sliding light sources in supports which are directly coupled together. This known solution, while maintaining the relative position between light source and lens, does not allow movements in directions other than the light beam emission direction. Similar solutions are disclosed in EP3258161A1, EP3808601, KR2020100007316 and US20040240217.

For example, document EP3062013A1 discloses an assembly of two light sources and lenses which are associated in fixed relative positions with a single radiator, therefore even if the focal distance remains unchanged between the single source and the respective lens, the distance between the sources also necessarily remains unchanged.

[0017]. These known solutions, despite being modular in the construction of the light source, the lens thereof, and the radiator, and while allowing limited rotation or translation of the light source with respect to the heat sink thereof to allow adjustments to compensate for induced deformations, such as thermal deformations, leave unmet the need for a solution which allows for an overall morphological configuration of the light sources within the vehicle light device.

[0018]. Solution

[0019]. The present invention aims to provide a modular light source assembly in which the position within the light device can be at least linearly adjustable.

[0020]. These and other objects and advantages are achieved by an assembly according to claim 1. [0021]. Some advantageous embodiments are the subject of the dependent claims.

[0022]. The discussion of this solution showed how the suggested solution allows adjusting the position of each individual modular light source assembly to change the morphology of the object at will depending on the stylistic requirements of the vehicle where the light device is installed.

[0023]. By virtue of the suggested solutions, it is possible to meet various stylistic requirements with the same modular light source assembly, such as the overall dimensions to respect for inserting the modular light source assemblies into a vehicle light device, allowing intensive design, prototyping, validation and industrialization activities to be avoided.

[0024]. By virtue of the suggested solutions, the suggested modular light source assembly is inherently scalable in the morphology thereof, with no change in performance. The module is designed and industrialized just once and can be reused according to the needs of each vehicle or vehicle light device.

[0025]. The sliding movement of the modular light source assemblies in at least one direction, preferably two, e.g., orthogonal to each other, e.g., parallel to the light beam and orthogonal thereto, allows creating a relative offset between the modules, which is a peculiar shape factor as a whole. The various possible shapes ensure full freedom in the stylistic choice of the overall morphology. The locking mechanism of a given morphology is ensured, for example, by using micrometer screws with irreversible pitch.

[0026]. Each individual modular light source assembly, or module, comprises a PCB, an optical assembly or lens, a heat sink, and at least one, preferably two, adjustment screws, and can be potentially reused on an unlimited number of designs:

[0027]. - during pre-feasibility studies, a solution to be used directly on the standard vehicle is available;

[0028]. - the prototype can coincide with the standard version without additional cost;

[0029]. - the production of the molding tools is developed just once;

[0030]. the optical design is carried out just once and is reusable for a plurality of installations.

[0031]. Figures

[0032]. Further features and advantages of the modular light source assembly and the vehicle light device will become apparent from the following description of preferred embodiments thereof, given by way of non-limiting examples, with reference to the accompanying drawings, in which:

[0033]. - figure 1 shows an axonometric view of a detail of a vehicle where a vehicle light device or headlamp is housed, in which modular light source assemblies are provided;

[0034]. - figure 2 shows an axonometric view of a first embodiment of a modular light source assembly;

[0035]. - figure 3 shows an axonometric view of a plurality of three modular light source assemblies according to a second embodiment, where each modular light source assembly is by the side of the adjacent modular light source assembly;

[0036]. - figure 4 shows an axonometric view of the plurality of modular light source assemblies in figure 3 according to a different viewpoint on the lens or optical element side;

[0037]. - figure 5 shows an axonometric view of a detail of the plurality of modular light source assemblies in figure 3, where one of the modular light source assemblies is shown with parts separated where the lens or optical element is moved away from the printed circuit board, PCB or plate used to install the light source, the circuits and the connector, which in turn is moved away from the heat sink;

[0038]. - figure 6 shows an axonometric view of a plurality of two modular light source assemblies according to a further embodiment;

[0039]. - figures 7, 8, and 9 show an axonometric view with parts separated and from different viewpoints the plurality of two modular light source assemblies in figure 6;

[0040]. - figure 10 shows an axonometric section of the solution in figure 6 which shows how the lens or optical element faces the semiconductor light source or LED, how the lens with the lens support arms thereof is fixed to the printed circuit board, PCB, and then to the heat sink;

[0041]. - figure 11 shows an axonometric section of the solution in figure 6 in which the details of the vertical micrometer actuator are highlighted;

[0042]. - figure 12 shows an axonometric section of the solution in figure 6 in which the details of the horizontal micrometer actuator are highlighted;

[0043]. - figure 13 shows an axonometric view of a plurality of six modular light source assemblies according to a further embodiment where each modular light source assembly is linearly displaced with respect to the adjacent modular light source assembly by highlighting the position adjustment directions of each modular light source assembly;

[0044]. - figure 14 diagrammatically shows an axonometric view of a plurality of three modular light source assemblies in which, for simplicity and by way of mere example, only two of the horizontal micrometer actuators are coupled to feedback-controlled servomotors to adjust the relative position of each assembly according to a first horizontal linear sliding direction.

[0045]. Description of some preferred embodiments

[0046]. According to a general embodiment, a modular light source assembly (1) comprising at least one semiconductor light source (2), such as an LED, is provided.

[0047]. Said modular light source assembly (1) further comprises at least one lens (4) which receives light from the semiconductor light source (2) and diffuses it in a light beam. For example, said light beam is appropriately calculated to meet the requirements (high beam, low beam, front fog light, etc.) of the light functions in the automotive field according to regulations: ECE; CCC; FVMSS_108; SAE depending on the optics version.

[0048]. Said modular light source assembly (1) further comprises at least one printed circuit board (3), or PCB; where said semiconductor light source (2) is electrically mounted in contact with said printed electronic board (3). According to an embodiment, said printed electronic board (3) promotes heat disposal.

[0049]. Said modular light source assembly (1) further comprises at least one heat sink (5).

[0050]. Said printed circuit board (3) is mounted on said heat sink (5).

[0051]. Said heat sink (5) is adapted to dissipate the heat produced by the semiconductor light source (2) which passes to the printed circuit board (3).

[0052]. Advantageously, said assembly (1) comprises a guide plate (6).

[0053]. Said heat sink (5) is connected to said guide plate (6) in a sliding manner along a predetermined linear sliding direction (Xo or Xv).

[0054]. Said assembly (1) further comprises a micrometer actuator (7 or 8).

[0055]. Said micrometer actuator (7 or 8) is interposed between said heat sink (5) and said guide plate (6) and commands the mutual linear displacement between said heat sink (5) and said guide plate (6).

[0056]. According to an embodiment, said micrometer actuator (7 or 8) commands the mutual linear displacement between said heat sink (5) and said guide plate (6) in a controlled manner.

[0057]. According to an embodiment, said micrometer actuator (7 or 8) commands the mutual linear displacement between said heat sink

(5) and said guide plate (6) in a manually controlled manner.

[0058]. According to an embodiment, said micrometer actuator (7 or 8) is commanded in turn in a controlled manner.

[0059]. According to an embodiment, said micrometer actuator (7 or 8) is commanded in turn in a feedback-controlled manner.

[0060]. According to an embodiment, said micrometer actuator (7 or 8) is electro-actuated.

[0061]. According to an embodiment, said guide plate (6) comprises at least one guide housing (9 or 10) which extends along said linear sliding direction (Xo or Xv).

[0062]. Said heat sink (5) comprises at least one guide (11 or 12).

[0063]. Said guide (11 or 12) is geometrically coupled into said guide housing (9 or 10) so as to slide freely along said linear sliding direction (Xo or Xv).

[0064], According to an embodiment, said guide plate (6) comprises at least one guide housing (9 or 10) which extends along said linear sliding direction (Xo or Xv); and where said guide housing (9 or 10) has a dovetail-shaped cross profile.

[0065]. Said heat sink (5) comprises at least one guide (11 or 12); and where said guide (11 or 12) has a dovetail-shaped cross profile complementary to said dovetail-shaped cross profile of said guide housing (9 or 10).

[0066]. Said guide (11 or 12) is geometrically coupled into said guide housing (9 or 10) so as to slide freely along said linear sliding direction (Xo or Xv).

[0067]. According to an embodiment, said guide plate (6) comprises a first and a second guide housing (9 or 10) parallel to each other and which extend along said linear sliding direction (Xo or Xv); and where said first and second guide housings (9 or 10) have a dovetail-shaped cross profile.

[0068]. Said heat sink (5) comprises a first and a second guide (11 or 12); and where said first and second guides (11 or 12) have a dovetail-shaped cross profile complementary to said dovetail-shaped cross profile of said first and second guide housings (9 or 10).

[0069]. Said first and second guides (11 or 12) are geometrically coupled into said first and second guide housings (9 or 10), respectively, so as to slide freely along said linear sliding direction (Xo or Xv).

[0070]. According to an embodiment, said guide plate (6) comprises at least one guide housing (9) which extends along said linear sliding direction (Xo).

[0071]. Said heat sink (5) comprises at least one guide (11).

[0072]. Said guide (11) is geometrically coupled into said guide housing (9) so as to slide freely along said linear sliding direction (Xo).

[0073]. Said guide plate (6) comprises at least one further guide housing (10) which extends along a further linear sliding direction (Xv) incident, e.g., orthogonal, to said linear sliding direction (Xo).

[0074]. Said heat sink (5) comprises at least one further guide (12).

[0075]. Said further guide (12) is geometrically coupled into said further guide housing (10) so as to slide freely along said further linear sliding direction (Xv).

[0076]. According to an embodiment, said micrometer actuator (7 or 8) comprises at least one threaded housing (13 or 14) provided in said heat sink (5) or said guide plate (6).

[0077]. Said micrometer actuator (7 or 8) further comprises at least one micrometer screw (15 or 16) with mainly axial extension and rotatably accommodated in said at least one threaded housing (13 or 14). Said at least one micrometer screw (15 or 16) comprises at least one axial abutment (17 and/or 18).

[0078]. Said micrometer actuator (7 or 8) further comprises at least one rotary coupling element (19 or 20) which forms at least one axial counter-abutment adapted to abut against said at least one axial abutment (17 and/or 18). Said at least one rotary coupling element is embedded in one of said guide plate (6) or heat sink (5) where said at least one threaded housing (13 or 14) is not present.

[0079]. According to an embodiment, said micrometer actuator (7 or 8) comprises at least one threaded housing (13 or 14) provided in said heat sink (5) or said guide plate (6) and extending along an actuator axial direction (Xao or Xav).

[0080]. Said micrometer actuator (7 or 8) further comprises at least one micrometer screw (15 or 16) with mainly axial extension and rotatably accommodated in said at least one threaded housing (13 or 14). Said at least one micrometer screw (15 or 16) comprises a screw head (17) which forms a first axial abutment and a facing and spaced-apart push edge (18) which forms a second opposite axial abutment.

[0081]. Said micrometer actuator (7 or 8) further comprises at least one rotary coupling element (19 or 20) which forms a first axial counter-abutment adapted to abut against said first axial abutment of said screw head (17) and a second axial counter-abutment adapted to abut against said second opposite axial abutment of push edge (18).

[0082]. Said at least one rotary coupling element (19 or 20) comprises a rotary coupling element housing (21 or 22) open in a direction transverse to said actuator axial direction (Xao or Xav) which freely rotatably accommodates a push rod portion (23) of said at least one micrometer screw (15 or 16).

[0083]. Said at least one rotary coupling element is embedded in one of said guide plate (6) or heat sink (5) where said at least one threaded housing (13 or 14) is not present.

[0084]. According to an embodiment, said assembly (1) comprises a first micrometer actuator (7) which comprises at least a first threaded housing (13) provided in said heat sink (5).

[0085]. Said assembly (1) further comprises at least a first micrometer screw (15) with mainly axial extension and rotatably accommodated in said at least a first threaded housing (13). Said at least a first micrometer screw (15) comprises at least a first axial abutment (17 and/or 18).

[0086], Said assembly (1) further comprises at least a first rotary coupling element (19) which forms at least a first axial counter-abutment adapted to abut against said at least a first axial abutment (17 and/or 18). Said at least a first rotary coupling element is embedded in said guide plate (6).

[0087]. Said assembly (1) comprises a second micrometer actuator (8) which comprises at least a second threaded housing (14) provided in said guide plate (6).

[0088]. Said assembly (1) further comprises at least a second micrometer screw (16) with mainly axial extension and rotatably accommodated in said at least a second threaded housing (14). Said at least a second micrometer screw (16) comprises at least a second axial abutment (17 and/or 18).

[0089]. Said assembly (1) further comprises at least a second rotary coupling element (20) which forms at least a second axial counter-abutment adapted to abut against said at least a second axial abutment (17 and/or 18). Said at least a second rotary coupling element is embedded in said heat sink (5).

[0090]. Advantageously, said guide plate (6) comprises opposite guide plate sides (24, 25).

[0091]. Said first guide plate side (24) comprises at least a first guide housing (9) extending along a first linear sliding direction (Xo).

[0092]. Said second opposite guide plate side (25) comprises at least a second guide housing (10) extending along a second linear sliding direction (Xv).

[0093], According to an embodiment, said guide plate (6) comprises opposite guide plate sides (24, 25).

[0094]. Said first guide plate side (24) comprises at least a first guide housing (9) extending along a first linear sliding direction (Xo).

[0095]. Said second opposite guide plate side (25) comprises at least a second guide housing (10) extending along a second linear sliding direction (Xv) orthogonal to said first linear sliding direction (Xo).

[0096]. According to an embodiment, said first guide plate side (24) is geometrically connected to a first heat sink (5).

[0097]. Said first heat sink (5) comprises at least a first guide (11) geometrically connected to said first guide housing (9) so as to slide freely along said first linear sliding direction (Xo).

[0098]. Said second guide plate side (25) is geometrically connected to a second heat sink (5).

[0099]. Said second heat sink (5) comprises at least a second guide (12) geometrically connected to said second guide housing (10) so as to slide freely along said second linear sliding direction (Xv).

[00100]. Advantageously, said heat sink (5) comprises opposite heat sink sides (26, 27).

[00101]. Said first heat sink side (26) comprises at least a first guide (11) extending along a first linear sliding direction (Xo) and adapted to connect geometrically to a first guide housing (9) of a first guide plate (6).

[00102]. Said second opposite heat sink side (26) comprises at least a second guide (12) extending along a second linear sliding direction (Xv) and adapted to connect geometrically to a second guide housing (10) of a second guide plate (6).

[00103], According to an embodiment, said heat sink (5) comprises opposite heat sink sides (26, 27).

[00104]. Said first heat sink side (26) comprises at least a first guide (11) extending along a first linear sliding direction (Xo) and adapted to connect geometrically to a first guide housing (9) of a first guide plate (6).

[00105]. Said second opposite heat sink side (27) comprises at least a second guide (12) extending along a second linear sliding direction (Xv) orthogonal to said first linear sliding direction (Xo) and adapted to connect geometrically to a second guide housing (10) of a second guide plate (6).

[00106], According to an embodiment, said lens (4) comprises a lens cone (28), which faces with a first end thereof said semiconductor light source (2), e.g., an LED, and moves away from said first end by widening until it reaches a lens diffuser (29).

[00107]. Said lens (4) further comprises lens support arms (30), which protrude from said lens diffuser (29) towards said first end of lens cone (28) without reaching it and to connect said lens (4) to the printed circuit board (3), or PCB, to position the lens with the first end facing said semiconductor light source (2) and to direct the light beam according to a predetermined average light beam direction (X) and a predetermined light diffusion according to the shape of the lens diffuser (29). [00108]. According to an embodiment, said assembly (1) comprises at least one connecting bracket (31) for the connection with a vehicle light device (32).

[00109]. At least one of said heat sink (5) and/or guide plate (6) is connected to said at least one connecting bracket (31).

[00110]. According to an embodiment, said assembly (1) comprises at least one connecting bracket (31) for the connection with a vehicle light device (32).

[00111]. At least one of said heat sink (5) and/or guide plate (6) is connected to said at least one connecting bracket (31).

[00112]. Said at least one connecting bracket (31) is slidingly connected to said vehicle light device (32).

[00113]. The present invention further relates to a vehicle light device (32) comprising at least one assembly (1) according to any one of the embodiments described above.

[00114]. According to an embodiment, said device (32) comprises at least one pair of modular light source assemblies (1) connected to the same guide plate (6).

[00115]. According to an embodiment, said device (32) comprises at least one pair of modular light source assemblies (1) connected on opposite sides to the same guide plate (6).

[00116]. A first heat sink (5) slides relatively to said guide plate (6) in a controlled manner along a first sliding direction (Xo).

[00117]. A second heat sink (5) slides relatively to the guide plate (6) in a controlled manner along a second sliding direction (Xv).

[00118]. According to an embodiment, said device (32) comprises at least three modular light source assemblies (1) where three heat sinks (5) are connected together by interposing a guide plate (6) between each pair of heat sinks (5).

[00119]. According to an embodiment, said device (32) comprises at least one pair of three modular light source assemblies (1) each, where six heat sinks (5) are connected together by interposing a guide plate (6) between each pair of heat sinks (5).

[00120]. In order to meet specific, contingent needs, those skilled in the art can make several changes and adaptations to the above- described embodiments and can replace elements with others which are functionally equivalent, without however departing from the scope of the following claims.

[00121]. According to an embodiment, said guide plate (6) is a heat sink (5) associated with a printed circuit board (3) connected to a semiconductor light source (2) and a lens (4).

[00122]. By virtue of this provision, an assembly consisting of heat sink (5), electronic board (3), light source (2), and lens (4) is directly slidingly connected in at least one direction (Xo or Xv) to an adjacent assembly consisting of heat sink (5), electronic board (3), light source (2), and lens (4) avoiding the interposition of an additional component and making the vehicle light device more compact.

[00123]. According to an embodiment, each micrometer actuator (7,

8) is operatively coupled to an electro-actuator, e.g., commanded, e.g., commanded in a controlled manner, where said electro-actuator is arranged far from said assembly (1) and connected to said micrometer actuator (7, 8) by a flexible transmission to transmit rotation, power, and torque via a flexible component, e.g., a transmission as described in US4185473A.

LIST OF REFERENCE SYMBOLS Modular light source assembly semiconductor light source; LED printed circuit board; PCB or plate used to install the light source, circuits, and connector lens or optical element calculated for the correct light beam emission heat sink guide plate horizontal micrometer actuator vertical micrometer actuator horizontal guide housing vertical guide housing horizontal guide vertical guide threaded housing in heat sink threaded housing in guide plate horizontal micrometer screw vertical micrometer screw screw head push edge rotary coupling element of guide plate rotary coupling element of heat sink rotary coupling element housing of guide plate rotary coupling element housing of heat sink push rod portion first guide plate side second opposite guide plate side first heat sink side second opposite heat sink side lens cone lens diffuser lens support arms 31 connecting bracket

32 vehicle light device

33 vehicle

Xo horizontal linear sliding direction Xv vertical linear sliding direction

Xao axial direction of horizontal threaded housing made in the heat sink

Xav axial direction of vertical threaded housing made in the guide plate X average light beam direction