Ultrathin light-emitting word mark integrally formed based on PUR

Abstract

The invention provides a PUR-based integrally-formed ultrathin light-emitting character mark which comprises an integrated ultrathin character mark body composed of a PUR thin film shell layer, a PVD membrane layer, a shading layer and a PUR substrate which are sequentially arranged from outside to inside, and a patch type Mini LED flexible light bar module arranged on the inner side face of the PUR thin film shell layer. The PUR thin film shell layer is a PUR thin film formed through reaction injection molding, the PVD diaphragm layer is a light guide layer, microprism-shaped or scattering lattice points are processed on the inner surface of the PVD diaphragm layer through silk-screen printing, the shading layer is a light-proof layer arranged on the PVD diaphragm layer through co-injection molding or film covering, and the light-proof layer is a light-proof layer arranged on the PVD diaphragm layer through silk-screen printing. And the patch type Mini LED flexible light bar module is embedded and packaged on the side surface of the PUR film shell layer to form a side-in type light path. The car logo has the advantages that the car logo structure is light, thin and seamless, and the car logo has the integrally-formed high-light-transmittance crystal texture.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of vehicle identification, in particular to a super-thin light-emitting character sign based on PUR integrated molding. BACKGROUND

[0002] With the continuous upgrading of automobile intelligence and appearance aesthetics, light-emitting vehicle signs have become the core design elements for strengthening brand recognition and highlighting the technological quality of vehicles. However, integrating light-emitting technology into automobile signs requires addressing much more stringent technical challenges than ordinary commercial signs, and there are still many pain points to be solved in the existing technology:

[0003] 1. Complex structure and process: Traditional automobile light-emitting signs are usually assembled by metal / plastic base, plastic light guide, transparent cover and sealing parts. This multi-component assembly structure not only has many joints, which may cause potential water leakage, but also may produce abnormal noise in the vibration environment of vehicle driving, affecting the user experience.

[0004] 2. Difficult to adapt to the needs of automobile-level ultra-thin and curved surface: Modern automobile design pursues smooth and seamless visual integration, and requires ultra-thin and curved surface matching for vehicle signs. The traditional assembly structure is difficult to further compress the thickness due to the need to reserve the installation space of LED light source and sealing structure. At the same time, the complex body curve will lead to a sharp increase in the matching and sealing difficulty of multiple components, directly reducing the product yield.

[0005] 3. Insufficient weather resistance and reliability: Automobile signs need to withstand extreme outdoor environments, including strong ultraviolet radiation, high and low temperature cycles of-40℃ to 85℃ or above, rain erosion, car wash agent corrosion and stone impact, etc. In the traditional scheme, epoxy resin is prone to yellowing, acrylic material has poor scratch resistance, and the assembly joints are prone to cracking due to the difference in thermal expansion and cold shrinkage coefficient of each component, ultimately leading to sealing failure.

[0006] 4. Poor optical effect: There is an air gap between the light guide and the cover of the multi-component structure, which is easy to cause light loss and glare problems, making it difficult to achieve the "surface light emission" effect required by high-end vehicles, which is uniform, soft and particle-free; and the imaging points of LED lamp beads are clearly visible, with low visual quality.

[0007] 5. Insufficient production efficiency and consistency: The traditional process involves cutting, assembly, sealing and other multiple processes, which is highly dependent on manual operation. Even in large-scale production scenarios, it is difficult to ensure the quality consistency of all products, while increasing production costs. SUMMARY

[0008] In view of the above problems, the purpose of the present application is to provide a super-thin light-emitting letter mark based on PUR integrated molding, which is used to realize the lightness, thinness, seamless and integrated molding of the car mark structure, and to overcome the shortcomings of the prior art.

[0009] The present application provides a super-thin light-emitting letter mark based on PUR integrated molding, which comprises: an integrated super-thin letter mark composed of a PUR film shell layer, a PVD film layer, a light shielding layer and a PUR substrate arranged in turn from the outside to the inside, and a patch type Mini LED flexible light bar module arranged on the inner side of the PUR film shell layer; the PUR film shell layer is a PUR film formed by reaction injection molding, the PVD film layer is a light guide layer, the inner surface of the PVD film layer is processed with micro-prism or scattering dots by silk printing, the light shielding layer is a non-transparent layer coated on the PVD film layer, and the patch type Mini LED flexible light bar module is embedded and packaged in the side of the PUR film shell layer, forming a side-in type light path.

[0010] As a preferred embodiment of the present application, the PUR film shell layer is a PUR film with a thickness of 0.5-1.5mm.

[0011] As a preferred embodiment of the present application, the super-thin light-emitting letter mark is a super-thin light-emitting car mark.

[0012] As a preferred embodiment of the present application, the thickness of the PVD film layer is less than 0.25mm.

[0013] The advantages and positive effects of the present application are:

[0014] 1. The present application integrates the mask, light guide, light shielding part, base and sealing ring of the traditional car mark into one PUR shell, completely eliminating the water leakage, dust and abnormal sound problems caused by joints and interfaces, and having high structural integrity.

[0015] 2. The present application realizes the ultimate crystal texture, because the high-transmittance optical PUR material itself has very high transmittance and gloss, and the surface is as clear and transparent as crystal after solidification, and the texture is far superior to traditional PMMA / PC materials, and high-end appearance requirements can be achieved without subsequent spraying or coating.

[0016] 3. The present application has excellent weather resistance and durability, and the PUR material is naturally resistant to impact, wear, chemical corrosion and UV yellowing, and can resist outdoor harsh environment for a long time, maintaining long-lasting appearance and optical performance.

[0017] 4. The present application has excellent sealing protection, and the PUR material is firmly bonded with the shell, light guide and other substrates, forming perfect air and water tight sealing, providing the highest level of protection for the internal light source module and circuit.

[0018] 5. This invention adopts an LED side-lit layout combined with a precision microstructure light guide layer, which realizes the transformation of point light sources into extremely uniform surface light sources in an ultra-thin space, eliminating the "starry sky" LED graininess, and achieving light quality at the level of luxury cars. Attached Figure Description

[0019] Figure 1 This is an isometric view of the overall structure of this embodiment.

[0020] Figure 2 This is a schematic diagram of the overall structure of this embodiment.

[0021] Figure 3 This is a side view of the overall structure of this embodiment.

[0022] Figure 4 for Figure 3 Enlarged view of part A.

[0023] Figure description: 1. PUR thin film outer shell layer; 2. PVD film layer; 3. Light-shielding layer; 4. PUR substrate; 5. Mini LED flexible light strip module; 6. Heat dissipation microchannel. Detailed Implementation

[0024] In the following description, numerous specific details are set forth for illustrative purposes and to provide a thorough understanding of one or more embodiments. However, it will be apparent that these embodiments may also be implemented without these specific details. In other instances, well-known structures and devices are shown in block diagram form for ease of description of one or more embodiments.

[0025] This embodiment of an ultra-thin luminous sign based on PUR integral molding includes: an integral ultra-thin sign composed of a PUR thin film shell layer 1, a PVD film layer 2, a light-shielding layer 3, and a PUR substrate 4 arranged sequentially from the outside to the inside; and a patch-type Mini LED flexible light strip module 5 disposed on the inner side of the PUR thin film shell layer 1. The PUR thin film shell layer 1 is a PUR thin film formed by reaction injection molding. The PVD film layer 2 is a light guide layer, and the inner surface of the PVD film layer 2 is screen-printed with microprism-shaped or scattering dots. The light-shielding layer 3 is an opaque layer coated on the PVD film layer. The patch-type Mini LED flexible light strip module 5 is embedded and encapsulated on the side of the PUR thin film shell layer 1 to form a side-entry light path. The thickness of the PUR thin film in the PUR thin film shell layer 1 is 0.5-1.5 mm. The ultra-thin luminous sign is an ultra-thin luminous car logo. The thickness of the PVD film layer 2 is less than 0.25 mm.

[0026] In this embodiment, the addition of a heat dissipation microchannel 6 enables heat dissipation of the surface-mount Mini LED flexible light strip module 5.

[0027] In this embodiment, the PUR film outer shell layer 1 serves as the outermost layer of the car logo. A 0.5-1.5mm thick PUR film is injection molded using a mold. Its outer surface undergoes UV varnish coating and curing treatment to form a wear-resistant and scratch-resistant hardened layer with a hardness of 6H or higher. This layer also possesses high light transmittance and excellent stone-piercing resistance.

[0028] In this embodiment, the PVD film layer 2 is firmly bonded to the back of the self-healing, highly transparent PUR film shell layer 1. The PVD film layer 2 has a thickness of 0.25 mm, and its inner surface (the side facing away from the transparent layer) is precisely designed with microprism structures or scattering dots through screen printing or pretreatment. These optical structures are simulated and optimized to guide light from the side-mounted LED to undergo total internal reflection within the thin layer and be uniformly emitted from the front, achieving a surface-emitting effect.

[0029] In this embodiment, the light-shielding layer 3 is formed on the back of the PVD film layer 2 using co-injection molding or coating technology. This layer is typically high-gloss black, chrome, or the same color as the car body, forming the background of the car logo. It can both conceal the internal structure and present a high-end metallic or solid color texture when not emitting light during the day.

[0030] The surface-mount Mini LED flexible light strip module 5 in this embodiment uses high-temperature resistant, high-efficiency surface-mount LEDs, which are fixed to a flexible printed circuit board (FPC) using SMT technology. During injection molding, this Mini LED flexible light strip assembly is precisely embedded and encapsulated on the side or specific edge of the PUR material, forming a side-entry light path design. The heat generated by the LEDs can be dissipated through the PUR material and subsequent structures.

[0031] The processing technology of the surface-mount Mini LED flexible light strip module 5 in this embodiment is as follows:

[0032] Step S1: Fabrication of Mini LED flexible light strip. The blue light chip is transferred to a flexible substrate for die bonding. An optical sealing layer made of transparent epoxy resin is used to seal and fix the blue light chip on the flexible substrate. The flexible substrate is a flexible circuit board. The optical sealing layer is used to protect the blue light chip. A diffusing agent is added to the transparent epoxy resin material of the optical sealing layer. The diffusing agent is used to make the light emitted by the blue light chip more uniform.

[0033] Step S2: Fabrication of the PVD film. Dots are printed on the lower surface of a PVD film with a thickness of 0.25mm or more, or dots are formed by carbon dioxide laser. This allows the light from the Mini LED flexible light strip to enter from the side, be conducted within the PVD film, and have total internal reflection destroyed by the dots to form a uniform surface light source. A layer of adhesive film containing yellow phosphor is attached to the PVD film. The blue LED chip excites the yellow phosphor to form white light, thereby improving the light conversion efficiency and reducing energy loss.

[0034] Step S3: Install the Mini LED flexible light strip on the side of the PVD film and place a high reflectivity reflector sheet below the PVD film; thereby realizing the use of the Mini LED flexible light strip to emit light and enter the dotted PVD film from the side. The dot breaks the light and forms total internal reflection in the PVD film, so that the light enters the backlight cavity through the upper surface of the PC film to form a surface light source.

[0035] In this embodiment, the PUR substrate 4 serves as the bottom layer and is either solid or hollow. It is integrally formed with the layers above, providing structural rigidity. This substrate integrates mounting clips, positioning pins, and waterproof cable interfaces for quick and reliable connection and sealing with the vehicle body.

[0036] The working principle of the ultra-thin luminous car logo in this embodiment is as follows: After being powered on, the LED light source emits light, which is evenly diffused through the light guide layer and shines through the self-healing transparent surface layer to form a uniform luminous effect; the microchannel heat dissipation system removes heat through air convection to ensure that the LED works within a safe temperature range; the PUR integrated molding structure makes the light reflect completely within the font, achieving uniform luminous emission without dark areas.

[0037] The processing method of the ultra-thin luminous car logo in this embodiment:

[0038] 1. Mold preparation: Based on the 3D data of the car logo, manufacture a high-precision, mirror-polished mold with the required micro-optical structure engraved on the surface of the cavity.

[0039] 2. Preparation and placement of film inserts: The pre-hardened PVD film is high-pressure molded and cut, and placed into the mold cavity as the front mold.

[0040] 3. PUR multi-material integrated injection molding:

[0041] Molten transparent PUR material is injected into the cavity and perfectly fused with the outer surface of the PVD film.

[0042] The Mini LED flexible light strip module, which has been lit and tested, is precisely delivered into the designated position in the cavity using a robotic arm.

[0043] By rotating the mold, colored PUR material is injected to form a background light-blocking layer.

[0044] 4. Curing and post-treatment: After pressure holding and cooling, demold to obtain a complete, seamless car logo assembly, and finally install waterproof connectors.

[0045] By innovatively combining the properties of PUR materials with optical design, the problems of traditional illuminated signs such as being heavy, complex to assemble, and having uneven light effects have been solved, resulting in ultra-thin, high-brightness, and long-life illuminated sign products.

[0046] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. An ultra-thin illuminated sign based on PUR integral molding, characterized in that, include: An integrated ultra-thin lettering is composed of a PUR thin film shell layer, a PVD film layer, a light-shielding layer, and a PUR substrate arranged sequentially from the outside to the inside, and a patch-type Mini LED flexible light strip module disposed on the inner side of the PUR thin film shell layer; the PUR thin film shell layer is a PUR thin film formed by reaction injection molding, the PVD film layer is a light guide layer, the inner surface of the PVD film layer is screen-printed with microprism-shaped or scattering dots, the light-shielding layer is an opaque layer coated on the PVD film layer, and the patch-type Mini LED flexible light strip module is embedded and encapsulated on the side of the PUR thin film shell layer to form a side-entry light path.

2. The ultra-thin luminous lettering based on PUR integral molding according to claim 1, characterized in that, The outer shell layer of the PUR film is a PUR film with a thickness of 0.5-1.5 mm.

3. The ultra-thin luminous lettering based on PUR integral molding according to claim 1, characterized in that, The ultra-thin illuminated lettering is an ultra-thin illuminated car logo.

4. The ultra-thin luminous lettering based on PUR integral molding according to claim 1, characterized in that, The thickness of the PVD film layer is less than 0.25 mm.

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