Manufacturing method of light-weight uniform light-emitting vehicle logo

Abstract

The invention discloses a manufacturing method of a light-weight uniform-light-emitting vehicle logo. The manufacturing method comprises the following steps that 1, product surface patterns, colors, circuits and touch points are printed on a polycarbonate flexible membrane; step 2, pasting an electronic element and an LED lamp bead on a touch point on the front surface or the side surface of the polycarbonate flexible diaphragm through a microwave single-mode resonant cavity; 3, the printed polycarbonate flexible membrane is put into a high-pressure forming mold, and the 3D flexible lamp panel in the needed shape is manufactured; 4, an upper shell is subjected to injection molding firstly, and if the light-emitting vehicle logo emits light positively, a light uniformizing layer is arranged in the PC or PMMA upper shell; if the light-emitting vehicle logo emits light laterally, a light uniformizing layer, a light guide plate and a reflector plate are sequentially arranged in the PC or PMMA upper shell; then the lamp panel is subjected to reinforcement treatment, the upper shell is subjected to injection molding, and finally the vehicle logo upper shell and the vehicle logo lower shell are subjected to integrated injection molding. The light-emitting vehicle logo prepared by the method is uniform in light emitting, the thickness of parts can be as low as 5mm, and the weight can be reduced by 60-87.5%.

Description

Technical Field

[0001] The invention belongs to the technical field of automobile parts and relates to a luminous vehicle logo; specifically, it relates to a method for manufacturing a lightweight and uniform luminous vehicle logo. Background Art

[0002] As people need to travel in their daily lives, vehicles have become an indispensable means of transportation. People's requirements for automobile quality are also gradually increasing, with higher requirements for exterior decoration. While taking care of consumers, car companies usually design their car logos to be luminous in order to highlight their brand recognition. However, existing luminous car logos have the following disadvantages: (1) When using a positive luminous car logo, the lamp beads are arranged on a hard PCB board. Due to the requirement for uniform light distance, the Z-direction distance of the luminous car logo exceeds 8mm (usually 28-40mm); (2) The use of multiple parts assembly not only consumes assembly time, but also increases mold costs; (3) When using traditional flexible circuit printing technology, it is necessary to consider its high temperature resistance and cannot quickly, large-scale, and firmly paste the lamp beads to the flexible circuit; (4) The problem of LED lamp bead arrangement will cause the car logo to have visible uneven light and dark, and the difference in light guide structure (positive light and side light) is prone to visual deviation. Summary of the invention

[0003] In view of the above-mentioned technical problems and defects, the purpose of the present invention is to provide a method for making a lightweight and uniformly luminous vehicle logo. The method first starts from the design of flexible circuits and designs the entire process to better apply the characteristics of free bending, lightweight and high reliability of flexible circuit boards to luminous vehicle logos; secondly, the circuit is improved to solve the problems of dark areas, uneven brightness and "firefly" effect; finally, a combination of light guiding and light uniformity is designed to reduce the number of lamp beads while making the vehicle logo glow evenly.

[0004] To achieve the above object, the present invention adopts the following technical solution:

[0005] A method for manufacturing a lightweight and uniformly luminous vehicle logo, the method comprising the following steps:

[0006] Step 1. Surface printing:

[0007] Print product surface patterns, colors, backside circuits and touch points on polycarbonate flexible films;

[0008] Step 2. Circuit patch:

[0009] The electronic components and LED lamp beads are pasted on the circuits and touch points on the back of the polycarbonate flexible membrane through a microwave single-mode resonant cavity; multiple LED lamp beads are connected in series first and then in parallel to form an LED light strip; the electronic components include capacitor C1, capacitor C2, capacitor C3, capacitor C4, capacitor C5, capacitor C6, inductor L, resistor R1, resistor R2, resistor R3, resistor R4, and resistor R5; wherein one end of the inductor L is connected to the resistor R2, and the other end is connected to the capacitor C1 and the resistor R1; one end of the capacitor C1 is connected to the inductor L, and the other end is connected to the resistor R1; one end of the capacitor C2, capacitor C3, and capacitor C4 are connected to the chip, and the other end is connected to the ground; one end of the capacitor C5 is connected to the LED The positive pole of the light strip is connected, and the other end is connected to the negative pole of the LED light strip; one end of the capacitor C6 is connected to the negative pole of the LED light strip, and the other end is connected to the chip PIN pin; one end of the resistor R1 is connected to the capacitor C1, and the other end is connected to the chip; one end of the resistor R2 is connected to the inductor L, and the other end is connected to the positive pole of the LED light strip; both ends of the resistor R3 are connected to the chip respectively; one end of the resistor R4 and the resistor R5 are connected to the PWM debugging end, and the other end is connected to the VIN end and the negative pole of the LED light strip respectively; then decide whether to dispense glue according to whether the designed luminous car logo adopts positive light or side light; if the luminous car logo is positive light, use a glue dispenser to apply uniform light glue on the surface of the LED lamp bead; if the luminous car logo is side light, no uniform light glue is needed;

[0010] Step 3. Forming and stamping:

[0011] Put the printed polycarbonate flexible film into the high-pressure forming mold to make a 3D flexible light panel of the required shape, and then punch out the surrounding waste;

[0012] Step 4. In-mold injection molding:

[0013] Step 4.1. Injection mold the PC or PMMA upper shell. If the luminous car logo is positively luminous, a uniform light layer is set inside the PC or PMMA upper shell. The uniform light layer is composed of four layers of film. The four layers of film are upper diffusion film, upper brightness enhancement film, lower brightness enhancement film and lower diffusion film from top to bottom. The uniform light layer is used to perform uniform light treatment so that the light is evenly diffused (the light is evenly distributed in the entire upper shell of the car logo); if the luminous car logo is side-luminous, a uniform light layer is set inside the PC or PMMA upper shell. A light-homogenizing layer, a light guide plate, and a reflective sheet are sequentially arranged inside; the light-homogenizing layer is composed of four layers of membrane sheets, which are upper diffusion membrane, upper brightness enhancement membrane, lower brightness enhancement membrane, and lower diffusion membrane from top to bottom; the light guide plate is arranged below the lower diffusion membrane, and the light guide plate is directly opposite to the side-emitting LED lamp beads, and a mesh point is arranged at the bottom of the light guide plate; the reflective sheet is arranged at the bottom of the light guide plate; the point light source emitted by the LED lamp beads forms a uniform surface light source after passing through the reflective sheet and the light guide plate, and then is emitted after being homogenized by the light-homogenizing layer;

[0014] Step 4.2. Reinforce the 3D flexible light board. If the luminous car logo is positively luminous, put the 3D flexible light board and the reflective sheet into the injection mold and the upper shell for injection molding to form the upper assembly of the car logo; if the luminous car logo is side-luminous, put the 3D flexible light board into the injection mold and the upper shell for injection molding to form the upper assembly of the car logo;

[0015] Step 4.3. Injection mold the upper assembly of the vehicle logo in step 4.2 and the lower shell as one piece to form a luminous vehicle logo.

[0016] As a preferred embodiment of the present invention, in step 1, conductive silver paste is printed on the surface of the polycarbonate flexible film to form circuits and touch points.

[0017] As a preferred embodiment of the present invention, in step 3, the polycarbonate flexible membrane is formed by using high-pressure gas, and the high-pressure gas refers to a gas with a pressure greater than normal pressure.

[0018] As a preferred embodiment of the present invention, the light guide plate is printed with dot dots by screen printing or laser dotting.

[0019] As a preferred embodiment of the present invention, when the luminous vehicle logo is positively luminous, the lower shell is arranged inside the upper shell, and adhesive is provided on the bottom of the upper shell and the lower shell.

[0020] As a preferred embodiment of the present invention, when the luminous car logo is side-emitting, the LED lamp beads are arranged on the side of the lower shell, the light guide plate is arranged between the lower shell and the upper shell, and the upper shell and the lower shell are buckled and integrally injection molded to encapsulate the 3D flexible light board inside.

[0021] Advantages and beneficial effects of the present invention:

[0022] (1) The present invention designs a unique series-parallel circuit and simultaneously calculates the resistivity of the LED lamp beads arranged in the circuit. By connecting electronic components, it can ensure that the resistance passing through each LED lamp bead is the same, achieving a constant current effect, so that the brightness of the LED lamp beads can reach approximately the same result, solving the problems of dark areas, uneven brightness, and "firefly" effect of existing luminous car logos.

[0023] (2) The present invention uses a polycarbonate flexible film as a carrier and prints a conductive silver paste on the polycarbonate flexible film. This method can produce a 3D flexible light board of a desired shape, thereby meeting the needs of different vehicle logos.

[0024] (3) The manufacturing method provided by the present invention can print product surface patterns, colors, etc. on a polycarbonate flexible film, which has a higher degree of design freedom and functional integration. In addition, the method changes the structure of the traditional car logo, and the prepared luminous car logo conforms to the trend of lightweighting of the entire vehicle. The thickness of the luminous car logo components is lower (the thickness of the components can be as low as 5 mm, achieving ultra-thinness) and the weight is lighter (the weight can be reduced by 60%-87.5%, which is 82.1%-87.5% thinner than the traditional 28-40 mm thick luminous car logo).

[0025] (4) The present invention utilizes the selective heating characteristics of metal powder by microwave magnetic field to realize fast and efficient mounting of surface mount components on flexible circuits; the surface mount electronic components and surface mount LED lamp beads are pasted on the polycarbonate flexible membrane through a microwave single-mode resonant cavity, and the flexible membrane still maintains good bending characteristics after the electronic components are mounted; in addition, the resistance of the solder joints melted by the microwave magnetic field is very low, which is beneficial to improving the electrical performance of the flexible circuit; the use of microwave rapid surface mounting technology provides an effective method for rapid and large-scale mounting of surface components of flexible circuits, which is beneficial to promoting the development and commercialization of flexible circuits. If the LED can still light up normally after microwave rapid mounting, it indicates that the microwave magnetic field has not damaged it.

[0026] (5) The present invention adopts IME technology, which can arbitrarily design the shape of the light-emitting surface to achieve more free and diverse light-emitting effects. IME plastic-electric integrated injection molding packaging technology combines LED with traditional injection molding to achieve high integration, reduce space and assembly steps, significantly reduce manufacturing costs, achieve cost-effectiveness, and reduce post-processing.

[0027] (6) The method provided by the present invention can form an integrated injection molding of the luminous vehicle logo and the bumper, thereby forming an overall injection molding effect, solving the problem of matching the luminous vehicle logo with the surrounding environment parts. After the overall injection molding, the vehicle logo and the front bumper can be integrated. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 This is a flow chart of the method for making a luminous vehicle logo of the present invention;

[0029] Figure 2 It is a schematic diagram of the circuit design of the present invention;

[0030] Figure 3 This is a schematic diagram of the connection of each LED lamp bead of the present invention;

[0031] Figure 4 This is a schematic diagram of a positively luminous vehicle logo;

[0032] Figure 5 This is a schematic diagram of the decomposition of the uniform light layer and the reflective sheet in the positive light-emitting vehicle logo;

[0033] Figure 6This is a schematic diagram of the internal changes of light after glue is applied to a single LED lamp bead in the positive light logo;

[0034] Figure 7 This is a schematic diagram of a side-lit vehicle logo;

[0035] Figure 8 This is an exploded schematic diagram of the uniform light layer, light guide plate, and reflective sheet in the side-lit car logo;

[0036] Fig. 9 It is a schematic diagram of the light of the side-emitting vehicle logo being emitted through the guide plate;

[0037] Fig.10 This is a schematic diagram of the light from the side-lit car logo being emitted through the light guide plate and reflective sheet. DETAILED DESCRIPTION

[0038] In order to enable those skilled in the art to better understand the technical solution and advantages of the present invention, the present application is described in detail below in conjunction with the accompanying drawings, but it is not intended to limit the protection scope of the present invention.

[0039] like Figures 1 to 10 As shown, this embodiment provides a method for making a lightweight and uniformly luminous vehicle logo, the method comprising the following steps:

[0040] Step 1. Surface printing

[0041] Print product surface patterns, colors, circuits and touch points on polycarbonate flexible films;

[0042] Step 2. Circuit patch

[0043] The selective heating characteristics of metal powder by microwave magnetic field are utilized to realize fast and efficient mounting of surface mounted components on flexible circuits; specifically, electronic components and LED lamp beads O are pasted on the touch points on the front or side of polycarbonate flexible membrane through microwave single-mode resonant cavity; multiple LED lamp beads are connected in series first and then in parallel to form LED light strips to achieve the purpose of equal voltage and current; the electronic components include capacitor C1, capacitor C2, capacitor C3, capacitor C4, capacitor C5, capacitor C6, inductor L, resistor R1, resistor R2, resistor R3, resistor R4, and resistor R5; wherein, one end of inductor L is connected to resistor R2, and the other end is connected to capacitor C1 and resistor R1; one end of capacitor C1 is connected to inductor L, and the other end is connected to resistor R1; one end of capacitor C2, capacitor C3, and capacitor C4 are connected to chip (model: T PS92642-Q1), and the other end is connected to the ground; one end of capacitor C5 is connected to the positive electrode of the LED light strip, and the other end is connected to the negative electrode of the LED light strip; one end of capacitor C6 is connected to the negative electrode of the LED light strip (ground end), and the other end is connected to the chip PIN pin; one end of resistor R1 is connected to capacitor C1, and the other end is connected to the chip; one end of resistor R2 is connected to inductor L, and the other end is connected to the positive electrode of the LED light strip; both ends of resistor R3 are connected to the chip respectively; one end of resistor R4 and resistor R5 are connected to the PWM debugging end, and the other end is connected to the VIN end and the negative electrode of the LED light strip respectively; then decide whether to dispense glue according to whether the designed luminous car logo adopts positive light or side light; if the luminous car logo is positive light, use a glue dispenser to apply uniform light glue on the surface of the LED lamp bead; if the luminous car logo is side light, no uniform light glue is needed;

[0044] Step 3. Forming and stamping

[0045] The flexible polycarbonate flexible film still maintains good bending properties after the components are mounted. The printed polycarbonate flexible film is placed in a high-pressure forming mold to form a 3D flexible light board 2 of a desired shape, and then the surrounding waste is punched out;

[0046] Step 4. In-mold injection molding

[0047] Step 4.1. Injection mold a PC (polycarbonate) or PMMA (polymethyl methacrylate) upper shell 1. If the luminous car logo is positively luminous, a uniform light layer 5 is set inside the PC or PMMA upper shell 1. The uniform light layer 5 is composed of four layers of film, which are, from top to bottom, an upper diffusion film 51, an upper brightness enhancement film 52, a lower brightness enhancement film 53, and a lower diffusion film 54. The uniform light layer 5 is used to perform uniform light treatment so that the light is evenly diffused (the light is evenly distributed in the entire upper shell of the car logo); if the luminous car logo is side-luminous, a uniform light layer 5 is set on the PC or PMMA upper shell 1. The housing 1 is provided with a light-homogenizing layer 5, a light guide plate 7, and a reflective sheet 6 in sequence; the light-homogenizing layer 5 is composed of four layers of membranes, which are, from top to bottom, an upper diffusion membrane 51, an upper brightness enhancement membrane 52, a lower brightness enhancement membrane 53, and a lower diffusion membrane 54; the light guide plate 7 is arranged below the lower diffusion membrane 54, and the light guide plate 7 is directly opposite to the side-emitting LED lamp bead O, and a mesh point 71 is arranged at the bottom of the light guide plate 7; the reflective sheet 6 is arranged at the bottom of the light guide plate 7; the point light source emitted by the LED lamp bead O forms a uniform surface light source after passing through the reflective sheet 6 and the light guide plate 7, and then is emitted after being homogenized by the light-homogenizing layer 5;

[0048] Step 4.2. Reinforce the 3D flexible light board. If the luminous car logo is positively luminous, put the 3D flexible light board and the reflective sheet into the injection mold and the upper shell for injection molding to form the upper assembly of the car logo; if the luminous car logo is side-luminous, put the 3D flexible light board into the injection mold and the upper shell for injection molding to form the upper assembly of the car logo;

[0049] Step 4.3. Injection mold the upper assembly of the vehicle logo in step 4.2 and the lower shell as one piece to form a luminous vehicle logo.

[0050] In step 1 of this embodiment, conductive silver paste is printed on the surface of the polycarbonate flexible membrane to form circuits and touch points; in step 3, the polycarbonate flexible membrane is molded using high-pressure gas; specifically, the polycarbonate flexible membrane is pressed into the mold cavity by internal pressurization and axial force feeding to form it; for parts with curved axes, the polycarbonate flexible membrane needs to be pre-bent into a shape close to the part, and then pressurized into shape.

[0051] In step 4.1 of this embodiment, the upper diffusion film 51, the upper brightness enhancement film 52, the lower brightness enhancement film 53, and the lower diffusion film 54 are high-temperature optical films. Considering that the minimum injection molding temperature is 180°C, if conventional optical films are used, the injection molding requirements cannot be met. Therefore, this application uses high-temperature optical films. Regarding the selection of specific high-temperature optical films, those skilled in the art can refer to the prior art.

[0052] It should be noted that in this embodiment, those skilled in the art may refer to the prior art for the specific injection molding process of the upper shell, the vehicle logo upper assembly, etc. It is not an improvement point of the present application and will not be described in detail.

[0053] In this embodiment, the light guide plate 7 is printed with dot dots by screen printing or laser punching. The light emitted by the LED lamp bead O passes through the dot dots 71 on the light guide plate 7, destroying its total reflection in the PMMA material. According to the size, density and arrangement of the dot dots, the direction of the light is controlled upward to form a uniform surface light source.

[0054] Further, if Figure 4 and Figure 7 As shown, in this embodiment, when the luminous car logo is positively luminous, the lower shell is arranged inside the upper shell 1, and the bottom of the upper shell 1 and the lower shell 3 are provided with adhesive 4; when the luminous car logo is side-luminous, the LED lamp bead O is arranged on the side of the lower shell 3, and the light guide plate 7 is arranged between the lower shell 3 and the upper shell 1. The upper shell 1 and the lower shell 3 are buckled and the 3D flexible light board is encapsulated inside after integral injection molding.

[0055] Continue as Figure 4 and Figure 7 As shown, by adopting the method provided by the present invention, when the luminous car logo is positively luminous, the thickness of the upper shell 1 is 4.5mm, the thickness of the 3D flexible light board 2 is 0.7mm, the thickness of the lower shell 3 is 1.5mm, the thickness of the adhesive backing 4 is 0.5mm, and the lower shell 3 and the 3D flexible light board 2 are arranged in the upper shell 1, so the overall thickness of the luminous car logo can be reduced to 5mm; when the luminous car logo is side-luminous, the thickness of the upper shell 1 is 4.5mm, the thickness of the lower shell 3 is 1.5mm, and the upper shell 1 and the lower shell 2 are buckled, so the overall thickness of the luminous car logo can be reduced to 7mm, thereby solving the problem of the thickness of the existing luminous car logo.

[0056] In addition, the luminous vehicle logo provided by the present invention can also be integrally injection molded with an existing bumper to solve the problem of matching the luminous vehicle logo with surrounding environmental parts, and after integral injection molding, the vehicle logo and the front bumper can be seamlessly integrated.

[0057] The above specific examples are used to illustrate the present invention, which is only used to help understand the present invention and is not intended to limit the present invention. For those skilled in the art of the present invention, according to the idea of ​​the present invention, some simple deductions, deformations or substitutions can be made. Therefore, the protection scope of the present invention shall be based on the protection scope of the claims.

Claims

1. A method for making a lightweight and uniformly luminous vehicle logo, characterized in that: The method comprises the following steps: Step 1. Surface printing: Print product surface patterns, colors, circuits and touch points on polycarbonate flexible films; Step 2. Circuit patch: The electronic components and LED lamp beads are pasted on the touch points on the front or side of the polycarbonate flexible membrane through a microwave single-mode resonant cavity; multiple LED lamp beads are connected in series first and then in parallel to form an LED light strip; the electronic components include capacitor C1, capacitor C2, capacitor C3, capacitor C4, capacitor C5, capacitor C6, inductor L, resistor R1, resistor R2, resistor R3, resistor R4, and resistor R5; wherein one end of the inductor L is connected to the resistor R2, and the other end is connected to the capacitor C1 and the resistor R1; one end of the capacitor C1 is connected to the inductor L, and the other end is connected to the resistor R1; one end of the capacitor C2, capacitor C3, and capacitor C4 are connected to the chip, and the other end is connected to the ground; one end of the capacitor C5 is connected to the LED The positive pole of the light strip is connected, and the other end is connected to the negative pole of the LED light strip; one end of the capacitor C6 is connected to the negative pole of the LED light strip, and the other end is connected to the chip PIN pin; one end of the resistor R1 is connected to the capacitor C1, and the other end is connected to the chip; one end of the resistor R2 is connected to the inductor L, and the other end is connected to the positive pole of the LED light strip; both ends of the resistor R3 are connected to the chip respectively; one end of the resistor R4 and the resistor R5 are connected to the PWM debugging end, and the other end is connected to the VIN end and the negative pole of the LED light strip respectively; then decide whether to dispense glue according to whether the designed luminous car logo adopts positive light or side light; if the luminous car logo is positive light, use a glue dispenser to apply uniform light glue on the surface of the LED lamp bead; if the luminous car logo is side light, no uniform light glue is needed; Step 3. Forming and stamping: Put the printed polycarbonate flexible film into the high-pressure forming mold to make a 3D flexible light panel of the required shape, and then punch out the surrounding waste; Step 4. In-mold injection molding: Step 4.

1. Injection mold a PC or PMMA upper shell. If the luminous car logo is positively luminous, a uniform light layer is set inside the PC or PMMA upper shell. The uniform light layer is composed of four layers of film, which are, from top to bottom, an upper diffusion film, an upper brightness enhancement film, a lower brightness enhancement film, and a lower diffusion film. The uniform light layer is used to perform uniform light treatment to evenly diffuse the light. If the luminous car logo is side-luminous, a uniform light layer, a light guide plate, and a reflective plate are set inside the PC or PMMA upper shell in sequence. The uniform light layer is composed of four layers of film, which are, from top to bottom, an upper diffusion film, an upper brightness enhancement film, a lower brightness enhancement film, and a lower diffusion film. The light guide plate is set below the lower diffusion film, and the light guide plate is directly opposite to the side-luminous LED lamp beads, and dots are set at the bottom of the light guide plate. The reflective plate is set at the bottom of the light guide plate. The point light source emitted by the LED lamp beads passes through the reflective plate and the light guide plate to form a uniform surface light source, and then is uniformly treated by the uniform light layer and emitted. Step 4.

2. Reinforce the 3D flexible light board. If the luminous car logo is positively luminous, put the 3D flexible light board and the reflective sheet into the injection mold and the upper shell for injection molding to form the upper assembly of the car logo; if the luminous car logo is side-luminous, put the 3D flexible light board into the injection mold and the upper shell for injection molding to form the upper assembly of the car logo; Step 4.

3. Injection mold the upper assembly of the vehicle logo in step 4.2 and the lower shell as one piece to form a luminous vehicle logo.

2. The method for making a lightweight and uniformly luminous vehicle logo according to claim 1, characterized in that: In step 1, conductive silver paste is printed on the surface of the polycarbonate flexible film to form circuits and touch points.

3. The method for making a lightweight uniformly luminous vehicle logo according to claim 1, characterized in that: In step 3, the polycarbonate flexible membrane is formed by using high-pressure gas, wherein the high-pressure gas refers to a gas with a pressure greater than normal pressure.

4. The method for making a lightweight uniformly luminous vehicle logo according to claim 1, characterized in that: The light guide plate is printed with dot dots by screen printing or laser dotting.

5. The method for making a lightweight uniformly luminous vehicle logo according to claim 1, characterized in that: When the luminous vehicle logo is positively luminous, the lower shell is arranged inside the upper shell, and adhesive is provided on the bottom of the upper shell and the lower shell.

6. The method for making a lightweight uniformly luminous vehicle logo according to claim 1, characterized in that: When the luminous car logo is side-emitting, the LED lamp beads are arranged on the side of the lower shell, the light guide plate is arranged between the lower shell and the upper shell, and the upper shell and the lower shell are buckled and integrally injection-molded to encapsulate the 3D flexible light board inside.

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