Lighting module, method of manufacturing the same and lighting device

Abstract

The application discloses a lighting module, a manufacturing method thereof and a lighting device. The lighting module comprises a bottom plate, at least one light emitting element and a lens assembly. The light emitting element is located on the bottom plate. The lens assembly is located on a side of the light emitting element away from the bottom plate and comprises at least one lens part. The lens assembly is a molded structure layer which is at least adhered to a bearing surface of the at least one light emitting element. Since the lens assembly is a molded structure layer, the lens assembly can perform light distribution on the light emitting element, provide good waterproof oxygen performance and mechanical vibration resistance for the light emitting element, and has the advantages of low cost, high alignment accuracy, no need of fixing components such as buckles and the like.

Description

Technical Field

[0001] Embodiments of this disclosure relate to a lighting module, a method for manufacturing the same, and a lighting device. Background Technology

[0002] With continuous economic development and accelerated urbanization, the market for lighting devices is growing larger and larger. Typically, a lighting device may include one or more lighting modules, and a lighting module may include a light-emitting component, a sealing component, and a heat sink; the light-emitting component is used to emit light, the sealing component is used to seal the light-emitting component, and the heat sink is used to dissipate heat from the light-emitting element.

[0003] A light-emitting diode (LED) is a semiconductor light-emitting element. Typically, an LED consists of a semiconductor chip. By applying current to the semiconductor chip, excess energy is released through recombination of charge carriers in the semiconductor, causing photon emission, thereby enabling the semiconductor chip to emit light. Summary of the Invention

[0004] This disclosure provides a lighting module, its manufacturing method, and a lighting device. The lighting module includes a base plate, at least one light-emitting element, and a lens assembly. The light-emitting element is located on the base plate. The lens assembly is located on the side of the light-emitting element away from the base plate and includes at least one lens portion. The lens assembly is a molded structural layer, which is adhered at least to the bearing surface of the at least one light-emitting element. Because the lens assembly is a molded structural layer, meaning it is manufactured using a molding process, the molded structural layer and the light-emitting element can be in close contact without an air layer. This allows the light emitted by the light-emitting element to be directly distributed through the lens assembly, reducing light loss and improving light extraction efficiency. Furthermore, while distributing light to the light-emitting element, the lens assembly also provides good waterproof and oxygen-resistant properties and mechanical vibration resistance. It also has advantages such as low cost, high alignment accuracy, and no need for fasteners or other fixing components.

[0005] At least one embodiment of this disclosure provides a lighting module comprising: a base plate; at least one light-emitting element located on the base plate; and a lens assembly located on the side of the at least one light-emitting element away from the base plate, and including at least one lens portion; the lens assembly being a molded structural layer, the molded structural layer being adhered at least to the bearing surface of the at least one light-emitting element.

[0006] For example, in a lighting module provided in one embodiment of this disclosure, the at least one light-emitting element is directly disposed on the base plate, and the bearing surface is the surface of the base plate near the lens assembly.

[0007] For example, an embodiment of the present disclosure provides an illumination module that further includes: a circuit board located between the base plate and the lens assembly, wherein the at least one light-emitting element is disposed on the circuit board, and the bearing surface is the surface of the circuit board near the lens assembly.

[0008] For example, in a lighting module provided in one embodiment of this disclosure, the area of ​​the circuit board is smaller than the area of ​​the base plate, the base plate includes a first region and a second region surrounding the first region, the circuit board is located in the first region, and the molded structure layer is also adhered to at least the side surface of the circuit board and the second region of the base plate.

[0009] For example, in a lighting module provided in one embodiment of this disclosure, the molded structure layer is also adhered to the side of the at least one light-emitting element away from the base plate, and each of the light-emitting elements is in close contact with the molded structure layer.

[0010] For example, in a lighting module provided in one embodiment of this disclosure, the lighting module further includes: an anti-wear component, the lens component being a molded structural layer, and the distance between the top end of the anti-wear component away from the base plate and the base plate in a direction perpendicular to the base plate being greater than the distance between the top end of the lens component away from the base plate and the base plate in a direction perpendicular to the base plate.

[0011] For example, in a lighting module provided in one embodiment of this disclosure, the anti-wear ring includes a plurality of protrusions, which are spaced apart along the edge of the lens assembly. The distance between the top of each protrusion away from the base plate and the base plate in a direction perpendicular to the base plate is greater than the distance between the top of the lens assembly away from the base plate and the base plate in a direction perpendicular to the base plate.

[0012] For example, in an embodiment of the present disclosure, the lighting module includes at least one lens portion comprising a plurality of edge lens portions arranged along the edge of the lens assembly, the plurality of edge lens portions being offset from the plurality of protrusions.

[0013] For example, in a lighting module provided in one embodiment of this disclosure, the plurality of protrusions includes at least three protrusions, and the centers of the orthographic projections of the at least three protrusions on the base plate are not on the same straight line.

[0014] For example, in an embodiment of the lighting module provided in this disclosure, the anti-wear ring includes a continuous annular structure disposed along the edge of the lens assembly, wherein the angle between the annular structure and the base plate near the inner side of the lens assembly is greater than 120 degrees.

[0015] For example, in a lighting module provided in one embodiment of this disclosure, the anti-wear ring is integrally formed with the base plate.

[0016] For example, in a lighting module provided in one embodiment of this disclosure, the anti-wear component includes: at least one anti-wear portion, which is disposed on the base plate at a distance from the at least one lens portion, wherein the dimension of the at least one anti-wear portion in the direction perpendicular to the base plate is greater than the dimension of the lens portion in the direction perpendicular to the base plate.

[0017] For example, in a lighting module provided in one embodiment of this disclosure, the wear-resistant part is integrally formed with the at least one lens part.

[0018] For example, in a lighting module provided in one embodiment of this disclosure, the base plate includes a power cord hole configured to allow a power cord to pass through, and the at least one abrasion protection portion includes a first abrasion protection portion whose orthographic projection on the base plate at least partially overlaps with the power cord hole.

[0019] For example, in a lighting module provided in one embodiment of this disclosure, the base plate includes a positioning hole, and the at least one wear-resistant part includes a second wear-resistant part, the orthographic projection of the second wear-resistant part on the base plate at least partially overlapping the positioning hole.

[0020] For example, in a lighting module provided in one embodiment of this disclosure, the at least one anti-wear part includes at least three anti-wear parts, and the centers of the orthographic projections of the at least three anti-wear parts on the base plate are not on the same straight line.

[0021] For example, in a lighting module provided in one embodiment of this disclosure, the wear-resistant component includes: a base plate sidewall located at the edge of the base plate; and a light-transmitting plate disposed on the base plate sidewall and located on the side of the lens assembly away from the base plate.

[0022] For example, in a lighting module provided in one embodiment of this disclosure, the wear-resistant component further includes: a fixing buckle, disposed along the edge of the light-transmitting plate, and configured to fix the light-transmitting plate to the side wall of the base plate.

[0023] For example, in a lighting module provided in one embodiment of this disclosure, the wear-resistant component further includes: a fixing adhesive located between the light-transmitting plate and the side wall of the base plate to fix the light-transmitting plate to the side wall of the base plate.

[0024] For example, an embodiment of the present disclosure provides an illumination module that further includes a hardened layer, at least located on the surface of the at least one lens portion away from the base plate, wherein the hardened layer has a pencil hardness greater than 3H.

[0025] For example, in a lighting module provided in one embodiment of this disclosure, the material of the hardening layer is selected from at least one of ultraviolet curable adhesive, polyurethane resin, polysiloxane, and polysilazane.

[0026] For example, in an embodiment of the lighting module provided in this disclosure, the lens assembly is made of silicone or epoxy resin.

[0027] At least one embodiment of this disclosure also provides a lighting device that includes the lighting module described in any of the preceding claims.

[0028] At least one embodiment of this disclosure also provides a method for manufacturing a lighting module, comprising: setting at least one light-emitting element on a base plate; and using a molding process to set a lens assembly on the side of the at least one light-emitting element away from the base plate, the lens assembly including at least one lens portion, the lens assembly being a molded structural layer, the molded structural layer being adhered at least to the bearing surface of the at least one light-emitting element. Attached Figure Description

[0029] To more clearly illustrate the technical solutions of the embodiments of this disclosure, the accompanying drawings of the embodiments will be briefly described below. Obviously, the drawings described below only relate to some embodiments of this disclosure and are not intended to limit this disclosure.

[0030] Figure 1A A schematic diagram of a lighting module provided in an embodiment of this disclosure;

[0031] Figure 1B This is a schematic diagram of an illumination module after the lens assembly has been removed, according to an embodiment of this disclosure.

[0032] Figure 2A A cross-sectional schematic diagram of a lighting module provided in an embodiment of this disclosure;

[0033] Figure 2B A cross-sectional schematic diagram of another lighting module provided in an embodiment of this disclosure;

[0034] Figure 3 A schematic diagram of another lighting module provided in an embodiment of this disclosure;

[0035] Figure 4 A schematic diagram of another lighting module provided in an embodiment of this disclosure;

[0036] Figure 5 A schematic diagram of another lighting module provided in an embodiment of this disclosure;

[0037] Figure 6 A schematic diagram of another lighting module provided in an embodiment of this disclosure;

[0038] Figure 7 A schematic diagram of another lighting module provided in an embodiment of this disclosure;

[0039] Figure 8A schematic diagram of another lighting module provided in an embodiment of this disclosure;

[0040] Figure 9 A cross-sectional schematic diagram of another lighting module provided in an embodiment of this disclosure; and

[0041] Figure 10 This is a schematic diagram of a lighting device provided in one embodiment of the present disclosure. Detailed Implementation

[0042] To make the objectives, technical solutions, and advantages of the embodiments of this disclosure clearer, the technical solutions of the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this disclosure. All other embodiments obtained by those skilled in the art based on the described embodiments of this disclosure without creative effort are within the scope of protection of this disclosure.

[0043] Unless otherwise defined, the technical or scientific terms used in this disclosure shall have the ordinary meaning understood by one of ordinary skill in the art to which this disclosure pertains. The terms “first,” “second,” and similar terms used in this disclosure do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as “comprising” or “including” mean that an element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as “connected” or “linked” are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect.

[0044] Because the performance of LEDs is highly susceptible to the effects of humidity, temperature, and mechanical vibration, LED lighting devices must possess excellent water and oxygen resistance and vibration resistance to ensure normal operation throughout their lifespan. Molding, which involves forming a lens assembly within the light-emitting element, effectively provides these properties. Furthermore, molding offers advantages such as low cost, high alignment accuracy, and the elimination of the need for fasteners or other fixing components.

[0045] In response, this disclosure provides a lighting module, its manufacturing method, and a lighting device. The lighting module includes a base plate, at least one light-emitting element, and a lens assembly. The at least one light-emitting element is located on the base plate. The lens assembly is located on the side of the at least one light-emitting element away from the base plate and includes at least one lens portion. The lens assembly is a molded structural layer, which is adhered at least to the bearing surface of the at least one light-emitting element. Because the lens assembly is a molded structural layer, meaning it is manufactured using a molding process, the molded structural layer and the light-emitting element can be in close contact without an air layer. This allows the light emitted by the light-emitting element to be directly distributed through the lens assembly, reducing light loss and improving light extraction efficiency. Furthermore, while distributing light to the light-emitting element, the lens assembly also provides good water and oxygen resistance and mechanical vibration resistance. It also offers advantages such as low cost, high alignment accuracy, and the elimination of the need for fasteners or other fixing components. On the other hand, the lighting module can also be equipped with an anti-wear component, which prevents the lens assembly from being scratched or worn during transportation, installation, and use, thereby improving the reliability and durability of the lighting module.

[0046] The lighting module, its manufacturing method, and the lighting device provided in the embodiments of this disclosure will now be described in detail with reference to the accompanying drawings.

[0047] One embodiment of this disclosure provides a lighting module. Figure 1A A schematic diagram of a lighting module provided in an embodiment of this disclosure; Figure 1B This is a schematic diagram of an illumination module after the lens assembly has been removed, according to an embodiment of this disclosure. Figure 1A and Figure 1B As shown, the lighting module 100 includes a base plate 110, at least one light-emitting element 120, and a lens assembly 130. The at least one light-emitting element 120 is located on the base plate 110. The lens assembly 130 is located on the side of the at least one light-emitting element 120 away from the base plate 110 and includes at least one lens portion 132. The lens assembly 130 is a molded structural layer, which is adhered at least to the bearing surface of the at least one light-emitting element 120. It should be noted that the adhesion of the molded structural layer to the bearing surface is not due to any other adhesive, but rather the material of the molded structural layer itself adheres to the bearing surface.

[0048] In the lighting module provided in this embodiment, the lens assembly is a molded structural layer, and this layer is adhered to at least one bearing surface of a light-emitting element. Specifically, the lens assembly is manufactured using a molding process with a colloid, and is integrally formed, including at least one lens portion. The molded structural layer and the light-emitting element can achieve close contact, without air gaps or other spacers. This allows light emitted from the light-emitting element to pass directly through the lens assembly without passing through other spacers (e.g., air gaps). Therefore, the molded structural layer can directly distribute light through the lens assembly, reducing light loss and improving light extraction efficiency. Furthermore, while directly distributing light to the light-emitting element, the lens assembly adhered to the bearing surface possesses strong water and oxygen isolation properties and good mechanical properties, thus providing the light-emitting element with excellent water and oxygen resistance and resistance to mechanical vibration. Additionally, the lens assembly using the molded structural layer also has advantages such as low cost, high alignment accuracy, and no need for fasteners or other fixing components. It should be noted that the alignment accuracy mentioned above refers to the alignment accuracy between the lens portion and the light-emitting element.

[0049] In the lighting module provided in this embodiment, the molded structure layer 130 is also adhered to the side of at least one light-emitting element 120 away from the base plate, and each light-emitting element 120 is in close contact with the molded structure layer 130. It should be noted that when the light-emitting element is an organic light-emitting diode, the light-emitting element can be an unencapsulated light-emitting diode chip or an encapsulated light-emitting diode.

[0050] Figure 2A A cross-sectional schematic diagram of a lighting module provided in an embodiment of this disclosure; Figure 2B This is a cross-sectional schematic diagram of another lighting module provided in one embodiment of this disclosure. (See diagram below.) Figure 1A , Figure 1B , Figure 2A and Figure 2B As shown, the lighting module 100 also includes a circuit board 190 located between the base plate 110 and the lens assembly 130, with at least one light-emitting element 120 disposed on the circuit board 190. The circuit board 190 can be fixed to the base plate 110, for example, by screws 195. In this case, as... Figure 2B As shown, at least one light-emitting element 120 is disposed on the circuit board 190, and the bearing surface 127 is the surface of the circuit board 190 near the lens assembly 130.

[0051] In some examples, such as Figure 2AAs shown, the base plate 110 includes a power cord hole 114 and a positioning hole 116; the power cord hole 114 is configured to allow a power cord 180 to pass through, and the positioning hole 116 is used for positioning the circuit board 190 and the base plate 110. For example, the circuit board 190 can be secured to the base plate 110 by passing a screw 195 through the circuit board 190 and extending into the positioning hole 116.

[0052] Of course, the embodiments disclosed herein include, but are not limited to, the at least one light-emitting element described above can also be directly disposed on the base plate. In this case, the base plate can serve as a substrate supporting the at least one light-emitting element, or as a circuit board providing driving power and driving signals to the at least one light-emitting element. For example, the circuit structure on the circuit board can be directly fabricated on the base plate, thereby reducing the thickness of the lighting module.

[0053] In some examples, at least one light-emitting element 120 is directly mounted on the base plate 110, with the bearing surface being the surface of the base plate 110 near the lens assembly 130.

[0054] In some examples, such as Figure 2B As shown, the area of ​​the circuit board 190 is smaller than the area of ​​the base plate 110. The base plate 110 includes a first region 111 and a second region 112 surrounding the first region 111. The circuit board 190 is located in the first region 111. The molding structure layer is also adhered to at least the side surface 192 of the circuit board 190 and the second region 112 of the base plate 110. Thus, the molding structure layer adheres not only to the bearing surface of at least one light-emitting element 120, but also to the side surface 192 of the circuit board 190 and the second region 112 of the base plate 110, thereby protecting and sealing the side surface of the circuit board. Therefore, this lens assembly can better provide the light-emitting element with good water and oxygen resistance and mechanical vibration resistance.

[0055] In some examples, such as Figure 1A and Figure 1B As shown, the lighting module 100 also includes an anti-wear component 140; the distance between the top end of the anti-wear component 140 away from the base plate 110 and the base plate 110 in a direction perpendicular to the base plate 110 is greater than the distance between the top end of the lens assembly 130 away from the base plate 110 and the base plate 110 in a direction perpendicular to the base plate 110. It should be noted that the lens portion 132 can be correspondingly disposed with the light-emitting element 120 to distribute light to the light-emitting element 120. For example, here, "direction perpendicular to the base plate" refers to a direction perpendicular to the main surface of the base plate. For example, the main surface of the base plate may not be strictly planar; for example, more than 80% of the area of ​​the main surface of the base plate lies in the same plane, and the aforementioned direction perpendicular to the base plate is a direction perpendicular to that plane. In some examples, "direction perpendicular to the base plate" may refer to the thickness direction of the base plate.

[0056] In the lighting module provided in this example, the module also includes an anti-wear component. The distance between the top of the anti-wear component and the base plate in a direction perpendicular to the base plate is greater than the distance between the top of the lens assembly and the base plate in a direction perpendicular to the base plate. Therefore, this anti-wear component can prevent the lens assembly, especially the lens portion, from being scratched or worn by other objects (such as gravel, the ground, or the mounting surface) during transportation, installation, and use. This avoids wear or scratches on the lens assembly manufactured using the molding process, thereby improving the reliability and durability of the lighting module. It should be noted that the high alignment accuracy mentioned above refers to the high alignment accuracy between the lens portion and the light-emitting element in the lens assembly. Furthermore, since the lens assembly manufactured using the molding process has lower hardness, it is easily worn or scratched, affecting the light distribution effect. The lighting module provided in this embodiment uses an anti-wear component, thereby preventing the lens assembly from being scratched and worn, and thus improving the reliability and durability of the lighting module.

[0057] For example, the aforementioned light-emitting element can be a light-emitting diode (LED) chip. Therefore, this lighting module has advantages such as high luminous efficiency and energy saving and environmental friendliness.

[0058] In some examples, the lens assembly is made of silicone or epoxy resin. This facilitates the formation of the lens assembly using molding processes. Of course, embodiments of this disclosure include, but are not limited to, other suitable materials may also be used for the lens assembly.

[0059] For example, the Shore hardness of the lens assembly is around 50. Of course, embodiments disclosed herein include, but are not limited to, this.

[0060] In some examples, such as Figure 1A and Figure 1B As shown, the anti-wear component 140 includes an anti-wear ring 150, which is disposed around the edge of the lens assembly 130. The distance between the top end of the anti-wear ring 150 away from the base plate 110 and the base plate 110 in a direction perpendicular to the base plate 110 is greater than the distance between the top end of the lens assembly 130 away from the base plate 110 and the base plate 110 in a direction perpendicular to the base plate 110. Therefore, by providing the anti-wear ring 150 at the edge of the lens assembly 130, the lighting module can both prevent the anti-wear ring 150 from affecting the light emission of the light-emitting element 120 and protect the lens assembly 130 from scratches and wear.

[0061] In some examples, such as Figure 1A and Figure 1BAs shown, the anti-wear ring 150 includes a plurality of protrusions 152, which are spaced apart along the edge of the lens assembly 130. The distance between the top of each protrusion 152 away from the base plate 110 and the base plate 110 in a direction perpendicular to the base plate 110 is greater than the distance between the top of the lens assembly 130 away from the base plate 110 and the base plate 110 in a direction perpendicular to the base plate 110. Therefore, the plurality of protrusions 152 spaced apart along the edge of the lens assembly 130 can further reduce the impact on the light emission of the light-emitting element 120, and can also protect the lens assembly 130 from scratches and wear.

[0062] In some examples, such as Figure 1A As shown, the at least one lens portion 132 described above includes a plurality of edge lens portions 1321 arranged along the edge of the lens assembly 130, and the plurality of edge lens portions 1321 are staggered with the plurality of protrusions 152. That is, the orthographic projections of the plurality of edge lens portions 1321 on the anti-wear ring 150 are spaced apart from the centers of the plurality of protrusions 152, and even the orthographic projections of the plurality of edge lens portions 1321 on the anti-wear ring 150 do not overlap with the plurality of protrusions 152. This can further reduce the influence of the plurality of protrusions 152 on the light emission of the light-emitting element 120.

[0063] For example, such as Figure 1A As shown, the plurality of lens portions 132 also include a plurality of intermediate lens portions 1322, located inside the plurality of edge lens portions 1321. It should be noted that the shape and size of the aforementioned edge lens portions and intermediate lens portions may be approximately the same, their difference being their positions.

[0064] In some examples, such as Figure 1A and Figure 1B As shown, the plurality of protrusions 152 includes at least three protrusions 152, and the centers of the orthographic projections of the at least three protrusions 152 on the base plate 110 are not on the same straight line. Thus, when the lens assembly of the lighting module is placed facing the orientation, the at least three protrusions can stably support the lighting module, thereby preventing the lens assembly from contacting the mounting surface or the ground, thus avoiding scratches and wear.

[0065] In some examples, such as Figure 1A and Figure 1B As shown, the protrusion 152 is a toothed protrusion. However, the embodiments of this disclosure include, but are not limited to, the protrusion can also be a dotted protrusion, a triangular protrusion, etc., as long as the highest point of the protrusion is higher than the highest point of the lens.

[0066] In some examples, such as Figure 1A and Figure 1BAs shown, the wear-resistant ring 150 is integrally formed with the base plate 110, thereby reducing the complexity of the lighting module and improving the reliability and durability of the product. For example, the wear-resistant ring and the base plate can be integrally formed using a die-casting process, thereby reducing manufacturing costs while maintaining good quality. Of course, embodiments of this disclosure include, but are not limited to, the wear-resistant ring can also be a separate or movable component and can be mounted on the base plate.

[0067] Figure 3 This is a schematic diagram of another lighting module provided according to an embodiment of this disclosure. Figure 3 As shown, the anti-wear ring 150 and the base plate 110 are detachable components.

[0068] In some examples, such as Figure 1A and Figure 1B As shown, the lighting module 100 also includes a heat sink 185 located on the side of the base plate 110 away from the lens assembly 130.

[0069] For example, the heat sink 185 may be integrally formed with the base plate 110. For example, the heat sink 185 may include a plurality of heat dissipation fins 1850. Of course, embodiments of this disclosure include, but are not limited to, the heat sink and the base plate may also be independent components.

[0070] For example, at least one lens portion 132 of the lens assembly 130 may be provided in a one-to-one correspondence with at least one light-emitting element 120, so that one lens portion alone distributes light for one light-emitting element. However, embodiments of this disclosure include, but are not limited to, multiple light-emitting elements may correspond to one lens portion, and the lens portion distributes light for multiple light-emitting elements.

[0071] Figure 4 This is a schematic diagram of another lighting module provided according to an embodiment of this disclosure. Figure 4 As shown, the anti-wear ring 150 may not have the aforementioned protrusion, but instead be a continuous annular structure 154 along the edge of the lens assembly 130. The angle between the inner surface of the annular structure 154 near the lens assembly 130 and the base plate 110 is greater than 120 degrees. In this case, the anti-wear ring can better prevent the lens assembly from contacting the mounting surface or the ground, thus avoiding scratches and wear. Furthermore, since the angle between the inner surface of the annular structure near the lens assembly and the base plate is greater than 120 degrees, the annular structure can also avoid affecting the light emission of the light-emitting element.

[0072] In some examples, such as Figure 4 As shown, the anti-wear ring 150, namely the aforementioned ring structure 154, is integrally formed with the base plate 110, thereby reducing the complexity of the lighting module and improving the reliability and durability of the product. For example, the anti-wear ring and the base plate can be integrally formed using a die-casting process, thereby reducing manufacturing costs while maintaining good quality.

[0073] Figure 5 This is a schematic diagram of another lighting module provided according to an embodiment of this disclosure. Figure 5 As shown, the anti-wear assembly 140 includes at least one anti-wear portion 142, which is spaced apart from the at least one lens portion 132 and disposed on the base plate 110. The dimension of the at least one anti-wear portion 142 in the direction perpendicular to the base plate 110 is larger than the dimension of the lens portion 132 in the same direction. Therefore, by providing at least one anti-wear portion 142 spaced apart from the at least one lens portion 132 on the base plate 110, and by ensuring that the dimension of the at least one anti-wear portion 142 in the direction perpendicular to the base plate 110 is larger than that of the lens portion 132, the lighting module can prevent the lens portion 142 in the lens assembly 130 from being scratched and worn, thereby improving the reliability and durability of the product. Furthermore, since the anti-wear portion 142 is spaced apart from the at least one lens portion 132, its impact on the light emission of the light-emitting element 120 is minimal.

[0074] In some examples, such as Figure 5 As shown, the wear-resistant part 142 is integrally formed with at least one lens part 132, thereby reducing the manufacturing difficulty and cost of the wear-resistant part.

[0075] In some examples, such as Figure 5 As shown, the base plate 110 includes a power cord hole 114 configured to allow a power cord 180 to pass through. At least one abrasion-resistant portion 142 includes a first abrasion-resistant portion 1421, the orthographic projection of which onto the base plate 110 at least partially overlaps with the power cord hole 114. That is, the first abrasion-resistant portion 1421 is positioned above the power cord hole 114. Since a power cord hole is typically required on the base plate, and the power cord hole is relatively large, its location would preclude the placement of a lens assembly. Therefore, by providing the aforementioned first abrasion-resistant portion, the space on the lens assembly can be cleverly utilized, and good protection for the lens assembly can be provided.

[0076] In some examples, such as Figure 5 As shown, the base plate 110 also includes a positioning hole 116; at least one anti-wear portion 142 includes a second anti-wear portion 1422, the orthographic projection of the second anti-wear portion 1422 on the base plate 110 at least partially overlapping with the positioning hole 116. That is, the second anti-wear portion 1422 is disposed above the positioning hole 116. Since positioning holes are usually required on the base plate, and the position of the positioning hole cannot accommodate the lens portion, the aforementioned second anti-wear portion cleverly utilizes the space on the lens assembly and provides good protection for the lens portion. It should be noted that the specific locations of the power cord hole 114 and the positioning hole 116 can be found in [reference needed]. Figure 2A .

[0077] In some examples, at least one abrasion protection portion 142 includes at least three abrasion protection portions 142, the centers of the orthographic projections of the at least three abrasion protection portions 142 on the base plate 110 are not on the same straight line. Thus, when the lens assembly of the lighting module is placed facing the orientation, the aforementioned at least three abrasion protection portions can stably support the lighting module, thereby preventing the lens assembly from contacting the mounting surface or the ground, thus avoiding scratches and wear.

[0078] Figure 6 This is a schematic diagram of another lighting module provided according to an embodiment of this disclosure. Figure 6 As shown, the wear-resistant assembly 140 includes a base plate sidewall 162 and a light-transmitting plate 164. The base plate sidewall 162 is located at the edge of the base plate 110 and has a certain height in a direction perpendicular to the base plate 110. The light-transmitting plate 164 is disposed on the base plate sidewall 162 and is located on the side of the lens assembly 130 away from the base plate 110. Thus, the lighting module can have the lens assembly disposed between the base plate sidewall and the light-transmitting plate, and the light-transmitting plate can protect the lens assembly, thereby preventing the lens assembly, especially the lens part, from being scratched and worn during transportation, installation, and use.

[0079] In some examples, such as Figure 6 As shown, the abrasion-resistant component 140 further includes a fixing buckle 166, disposed on the edge of the light-transmitting plate 164 and configured to fix the light-transmitting plate 164 to the side wall 162 of the base plate. Of course, embodiments of this disclosure include, but are not limited to, the abrasion-resistant component may also not have a fixing buckle, and the light-transmitting plate may be fixed to the side wall of the base plate in other ways.

[0080] Figure 7 This is a schematic diagram of another lighting module provided according to an embodiment of this disclosure. Figure 7 As shown, the abrasion-resistant assembly 140 further includes: a fixing adhesive 168, located between the light-transmitting plate 164 and the base plate sidewall 162 to fix the light-transmitting plate 164 to the base plate sidewall 162. It should be noted that in this lighting module, as... Figure 7 As shown, the light-transmitting plate 164 can be fixed to the base plate side wall 162 using both the fixing clip 166 and the fixing adhesive 168. Of course, the embodiments of this disclosure include, but are not limited to, the lighting module can also be fixed to the base plate side wall using only the fixing clip or the fixing adhesive.

[0081] Figure 8 This is a schematic diagram of another lighting module provided according to an embodiment of this disclosure. Figure 8As shown, the anti-wear component 140 includes a base plate sidewall 162 and a light-transmitting plate 164. The base plate sidewall 162 is located at the edge of the base plate 110 and has a certain height in a direction perpendicular to the base plate 110. The light-transmitting plate 164 is disposed on the base plate sidewall 162 and is located on the side of the lens assembly 130 away from the base plate 110. The lighting module can form a receiving cavity 201 through the base plate sidewall 162 and the light-transmitting plate 164, and the lens assembly 130 is disposed in the receiving cavity 201, thereby preventing the lens assembly, especially the lens part, from being scratched and worn during transportation, installation and use in lamp housings with glass covers, etc.

[0082] In some examples, such as Figure 8 As shown, the lighting module 100 also includes a fixing component 169, which is disposed at the corner of the light-transmitting plate 164 to fix the light-transmitting plate 164 to the side wall 162 of the base plate.

[0083] In some examples, such as Figure 8 As shown, the lighting module 100 also includes a sealing assembly 172 disposed between the base plate sidewall 162 and the light-transmitting plate 164 to seal the aforementioned accommodating cavity 201. Thus, the light-emitting element and lens assembly can be disposed within the cavity formed by the base plate, the base plate sidewall, and the light-transmitting plate. This cavity forms a sealed space, making it difficult for dust to accumulate and for water and oxygen to enter, thereby providing good protection for the light-emitting element and lens assembly.

[0084] In some examples, such as Figure 8 As shown, the lighting module 100 also includes a power supply cavity 175 and a power supply assembly 176 disposed within the power supply cavity 175, the power supply assembly 176 being used to provide power to the light-emitting element.

[0085] In some examples, such as Figure 8 As shown, the lighting module 100 also includes a mounting bracket 177, which can be used to install the lighting module 100.

[0086] Figure 9 This is a cross-sectional schematic diagram of another lighting module provided in one embodiment of this disclosure. (See diagram below.) Figure 9 As shown, the lighting module 100 also includes a hardening layer 170, located at least on the surface of at least one lens portion 132 away from the base plate 110. The hardening layer 170 has a pencil hardness greater than 3H. Therefore, the hardening layer 170 located on the surface of the lens portion 132 away from the base plate 110 also protects the lens portion 132, preventing its surface from being scratched and worn by other objects, such as sand or gravel, thereby further improving the reliability and durability of the lighting module. Furthermore, the surface of the hardening layer is denser than the surface of the lens portion, thus preventing dust accumulation.

[0087] For example, the material of the hardening layer 170 is selected from at least one of ultraviolet-curable adhesive, polyurethane resin, polysiloxane, and polysilazane. Of course, the embodiments disclosed herein are not limited to this, and the hardening layer described above may also be made of other materials.

[0088] For example, the hardened layer described above can be formed using a spraying process. Of course, the embodiments disclosed herein are not limited to this, and the hardened layer described above can also be formed using other suitable processes.

[0089] One embodiment of this disclosure also provides a lighting device. Figure 10 This is a schematic diagram of a lighting device provided according to an embodiment of the present disclosure. Figure 10 As shown, the lighting device 200 includes the aforementioned lighting module 100. Therefore, the lighting device also possesses the beneficial effects corresponding to those of the aforementioned lighting module, which will not be elaborated further here; please refer to the relevant description of the lighting module for details.

[0090] In some examples, the lighting device can be a street light, stadium light, airport light, etc.

[0091] One embodiment of this disclosure also provides a method for manufacturing a lighting module, which includes: setting at least one light-emitting element on a base plate; and using a molding process to set a lens assembly on the side of the at least one light-emitting element away from the base plate, the lens assembly including at least one lens portion, the lens assembly being a molded structural layer, the molded structural layer being adhered at least to the bearing surface of the at least one light-emitting element.

[0092] In the manufacturing method of the lighting module provided in this embodiment, a lens assembly is disposed on the side of at least one light-emitting element away from the base plate using a molding process. The lens assembly is a molded structural layer, and this layer can adhere to the bearing surface of at least one light-emitting element. Therefore, while distributing light to the light-emitting element, the lens assembly adhered to the bearing surface has strong water and oxygen isolation properties and good mechanical properties, thus providing the light-emitting element with good water and oxygen resistance and mechanical vibration resistance. Furthermore, using a molding process to dispose of the lens assembly on the side of at least one light-emitting element away from the base plate also has advantages such as low cost, high alignment accuracy, and no need for fasteners or other fixing components. It should be noted that the alignment accuracy mentioned above refers to the alignment accuracy between the lens and the light-emitting element.

[0093] The following points need to be explained:

[0094] (1) The accompanying drawings of the embodiments of this disclosure only involve the structures involved in the embodiments of this disclosure. Other structures can be referred to the general design.

[0095] (2) Where there is no conflict, features of the same embodiment and different embodiments of this disclosure can be combined with each other.

[0096] The above are merely specific embodiments of this disclosure, but the scope of protection of this disclosure is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this disclosure should be included within the scope of protection of this disclosure. Therefore, the scope of protection of this disclosure should be determined by the scope of the claims.

Claims

1. A lighting module, comprising: Base plate; At least one light-emitting element is located on the base plate; as well as A lens assembly, located on the side of the at least one light-emitting element away from the base plate, and including at least one lens portion. The lens assembly is a molded structural layer, which is adhered at least to the bearing surface of the at least one light-emitting element. The lighting module further includes an anti-wear component, wherein the distance between the top edge of the anti-wear component and the base plate in a direction perpendicular to the base plate is greater than the distance between the top edge of the lens assembly and the base plate in a direction perpendicular to the base plate. The anti-wear assembly includes at least one anti-wear portion, which is spaced apart from the at least one lens portion and disposed on the base plate. The dimension of the at least one anti-wear portion in the direction perpendicular to the base plate is larger than the dimension of the lens portion in the same direction. The base plate includes a positioning hole. The at least one anti-wear portion includes a second anti-wear portion, the orthographic projection of which onto the base plate at least partially overlaps with the positioning hole. The second anti-wear portion is surrounded by a plurality of the lens portions, and the anti-wear portion is integrally formed with the at least one lens portion. The anti-wear component further includes an anti-wear ring, which is disposed around the edge of the lens assembly. The distance between the top end of the anti-wear ring away from the base plate and the base plate in a direction perpendicular to the base plate is greater than the distance between the top end of the lens assembly away from the base plate and the base plate in a direction perpendicular to the base plate. The anti-wear ring is integrally formed with the base plate. The wear-resistant component also includes a base plate sidewall located at the edge of the base plate and a light-transmitting plate, the light-transmitting plate being disposed on the base plate sidewall and located on the side of the lens assembly away from the base plate.

2. The lighting module according to claim 1, wherein, The at least one light-emitting element is directly disposed on the base plate, and the bearing surface is the surface of the base plate near the lens assembly.

3. The lighting module according to claim 1, further comprising: The circuit board is located between the base plate and the lens assembly. The at least one light-emitting element is disposed on the circuit board, and the bearing surface is the surface of the circuit board near the lens assembly.

4. The lighting module according to claim 3, wherein, The area of ​​the circuit board is smaller than the area of ​​the base plate. The base plate includes a first region and a second region surrounding the first region. The circuit board is located in the first region. The molded structural layer is also adhered to the side surface of the circuit board and the second region of the base plate.

5. The lighting module according to any one of claims 1-4, wherein, The molded structural layer is also adhered to the side of the at least one light-emitting element away from the base plate, and each light-emitting element is in close contact with the molded structural layer.

6. The lighting module according to any one of claims 1-4, further comprising: The heat sink is located on the side of the base plate away from the lens assembly.

7. The lighting module according to any one of claims 1-4, wherein, The light-emitting element is a light-emitting diode chip.

8. The lighting module according to claim 1, wherein, The wear-resistant ring includes a plurality of protrusions, which are spaced apart along the edge of the lens assembly. The distance between the top of each protrusion away from the base plate and the base plate in a direction perpendicular to the base plate is greater than the distance between the top of the lens assembly away from the base plate and the base plate in a direction perpendicular to the base plate.

9. The lighting module according to claim 8, wherein, The at least one lens portion includes a plurality of edge lens portions arranged along the edge of the lens assembly, the plurality of edge lens portions being offset from the plurality of protrusions.

10. The lighting module according to claim 9, wherein, The plurality of protrusions includes at least three protrusions, and the centers of the orthographic projections of the at least three protrusions on the base plate are not on the same straight line.

11. The lighting module according to claim 1, wherein, The anti-wear ring includes a continuous annular structure disposed along the edge of the lens assembly, wherein the angle between the annular structure and the base plate near the inner side of the lens assembly is greater than 120 degrees.

12. The lighting module according to claim 8, wherein, The protrusions are tooth-shaped protrusions, dot-shaped protrusions, or triangular protrusions.

13. The lighting module according to claim 9, wherein, The plurality of lens portions also include a plurality of intermediate lens portions located inside the plurality of edge lens portions.

14. The lighting module according to claim 9, wherein, The orthographic projections of the plurality of edge lenses onto the wear-resistant ring do not overlap with the plurality of protrusions.

15. The lighting module according to claim 13, wherein, The base plate includes a power cord hole configured to allow a power cord to pass through, and the at least one abrasion protection portion includes a first abrasion protection portion whose orthographic projection on the base plate at least partially overlaps with the power cord hole.

16. The lighting module according to claim 15, wherein, The at least one wear-resistant part includes two second wear-resistant parts, which are located on both sides of the first wear-resistant part.

17. The lighting module according to claim 13, wherein, The at least one wear-resistant part includes at least three wear-resistant parts, and the centers of the orthographic projections of the at least three wear-resistant parts on the base plate are not on the same straight line.

18. The lighting module according to claim 1, wherein, The side wall of the base plate and the light-transmitting plate form a receiving cavity, and the lens assembly is disposed in the receiving cavity.

19. The lighting module according to claim 1, wherein, The wear-resistant component also includes: A fixing buckle is provided along the edge of the light-transmitting plate and configured to fix the light-transmitting plate to the side wall of the base plate.

20. The lighting module according to claim 1, wherein, The wear-resistant component also includes: A fixing adhesive is placed between the light-transmitting plate and the side wall of the base plate to fix the light-transmitting plate to the side wall of the base plate.

21. The lighting module according to any one of claims 1-4, further comprising: A hardened layer is located at least on the surface of the at least one lens portion away from the base plate. The pencil hardness of the hardened layer is greater than 3H.

22. The lighting module according to claim 21, wherein, The material of the hardened layer is selected from at least one of ultraviolet curable adhesive, polyurethane resin, polysiloxane, and polysilazane.

23. The lighting module according to any one of claims 1-4, wherein, The lens assembly is made of silicone or epoxy resin.

24. A lighting device comprising a lighting module according to any one of claims 1-23.

25. A method for manufacturing a lighting module according to claim 1, comprising: At least one light-emitting element is placed on the base plate; as well as A lens assembly is disposed on the side of at least one light-emitting element away from the base plate using a molding process. The lens assembly includes at least one lens portion. The lens assembly is a molded structural layer, which is adhered at least to the bearing surface of the at least one light-emitting element.

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