Headlamp light-emitting diode structure and system thereof

Abstract

The invention discloses a headlamp light-emitting diode structure and a headlamp light-emitting diode system, and belongs to the technical field of automobile illumination, the headlamp light-emitting diode structure comprises a headlamp light-emitting diode structure, an intelligent driving circuit, an environment perception and intelligent control system and an energy recovery and management system.The heat dissipation efficiency is effectively improved by arranging a unique heat dissipation structure, and the heat dissipation efficiency is improved; the temperature of the LED chip is reduced, the light attenuation is reduced, the service life of the LED chip is prolonged, the frequency and cost for replacing the lamp are reduced, the design of the composite optical lens and the special reflection cup enables light distribution to be more uniform, the illumination range is wider, the driving safety at night and under complex road conditions is improved, and the driving safety is improved. By arranging the intelligent driving circuit and the environment sensing system, the LED chip is ensured to work stably in different environments and working conditions, and the problems of flickering and unstable brightness are avoided. Meanwhile, lighting parameters are automatically adjusted according to the environment and the vehicle speed, and the driving comfort and safety are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile lighting, and more particularly to a headlamp light emitting diode structure and a system thereof. Background Art

[0002] In the field of automotive lighting, the performance of headlights is crucial. At present, although the light-emitting diode (LED) technology used in automotive headlights has been widely used, it still has many shortcomings. The heat dissipation efficiency of the traditional LED structure is low. The high temperature generated in the engine compartment when the car is driving and the heat generated by the LED itself can easily cause the temperature of the LED chip to be too high, resulting in increased light decay, reduced lighting brightness and service life. Its optical design is also not precise enough, and the light is seriously scattered, which cannot effectively illuminate the distant and curved areas, affecting the driver's field of vision and posing a safety hazard. At the same time, the driving circuit of the existing headlight LED structure has poor stability and is easily affected by the voltage fluctuation of the automotive electrical system, causing the LED to flicker or unstable brightness, interfering with driving. Moreover, the overall system energy consumption is high, which is not conducive to energy conservation and emission reduction, and it is difficult to meet the needs of automobile manufacturers and consumers in terms of cost control.

[0003] Therefore, it is necessary to invent a headlight light emitting diode structure and a system thereof to solve the above problems. Summary of the invention

[0004] In order to overcome the above-mentioned defects of the prior art, the present invention provides a headlight LED structure and a system thereof to solve the problem that the driving circuit of the existing headlight LED structure proposed in the above-mentioned background technology has poor stability and is easily affected by voltage fluctuations in the automobile electrical system, causing LED flickering or unstable brightness, thereby interfering with driving.

[0005] In order to achieve the above-mentioned purpose, the present invention provides the following technical solutions: a headlight light-emitting diode structure, comprising a heat dissipation base, a ceramic heat sink fixedly connected to the heat dissipation base, an LED chip fixedly connected to the ceramic heat sink, a special curved reflector cup arranged above the LED chip, the curved surface of the special curved reflector cup being obtained by optimizing and calculating the mathematical model and optical design software, the surface of the special curved reflector cup being plated with a silver-aluminum composite coating, a composite optical lens being connected to the heat dissipation base, the composite optical lens being composed of an inner aspheric lens and an outer microprism array lens, a heat dissipation fin being also arranged on the ceramic heat sink, the heat dissipation fin being wavy and made of a high thermal conductivity aluminum alloy, a heat pipe being fixedly embedded in the heat dissipation fin and heat dissipation fins extending from both ends of the heat pipe, a heat conductive plate being fixedly connected to one end of the heat pipe, and the heat conductive plate being fixedly arranged above the heat dissipation base.

[0006] As a further description of the above technical solution, the LED chip electrode is made of a low-resistance metal material and an optimized energy well structure is adopted inside the LED chip, the two ends of the LED chip are respectively fixedly connected with an anode terminal and a cathode terminal, the anode terminal and the cathode terminal are respectively connected with an anode sheet and a cathode sheet, the outer side of the composite optical lens is sleeved with an external package, and the heat pipe is filled with acetone as a working medium; As a further description of the above technical solution, a headlight LED system includes the above automobile headlight LED structure, as well as an intelligent driving circuit, an environment perception and intelligent control system, and an energy recovery and management system; As a further description of the above technical solution, the intelligent driving circuit is based on digital control, adopts pulse width modulation technology, and integrates overvoltage protection, overcurrent protection and overheating protection functions; As a further description of the above technical solution, the environment perception and intelligent control system is equipped with an ambient light sensor, a vehicle speed sensor and a steering sensor, which can adjust the brightness, lighting range and lighting angle of the headlights according to the external light intensity, vehicle speed and steering angle; As a further description of the above technical solution, the energy recovery and management system converts kinetic energy into electrical energy when the vehicle brakes or decelerates and stores it in a supercapacitor, and provides a stable power supply for the headlight LED structure; As a further description of the above technical solution, the energy recovery and management system has a power management function and can intelligently distribute electrical energy; As a further description of the above technical solution, the supercapacitor is directly connected to the headlight light emitting diode structure.

[0007] Compared with the prior art, the present invention has the following beneficial effects: The present invention effectively improves the heat dissipation efficiency, reduces the temperature of LED chips, reduces light decay, prolongs the service life of LEDs, and reduces the frequency and cost of replacing lamps by setting a unique heat dissipation structure. The design of the composite optical lens and the special curved reflector cup makes the light distribution more uniform and the lighting range wider, improving driving safety at night and under complex road conditions. By setting an intelligent driving circuit and an environmental perception system, the LED is ensured to work stably in different environments and working conditions, avoiding flickering and unstable brightness. At the same time, the lighting parameters are automatically adjusted according to the environment and vehicle speed, improving driving comfort and safety; 2. The present invention improves energy utilization efficiency and reduces the overall energy consumption of the vehicle by providing an energy recovery and management system. By optimizing the structure and system design, the lighting performance is improved while reducing the cost of the overall system. From the perspective of long-term use, the maintenance and replacement costs are reduced, thereby improving the economic benefits of automobile manufacturers and consumers. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For ordinary technicians in this field, other drawings can also be obtained based on these drawings.

[0009] Figure 1 A schematic diagram of the internal structure provided by the present invention; Figure 2 A front view of the overall structure provided by the present invention; Figure 3 The present invention provides an overall structural diagram.

[0010] Description of reference numerals: 1. Heat sink; 2. Ceramic heat sink pad; 3. LED chip; 4. Anode terminal; 5. Cathode terminal; 6. Anode sheet; 7. Cathode sheet; 8. Special curved reflector cup; 9. Composite optical lens; 10. Heat sink fins; 11. Heat pipe; 12. Thermal conductive sheet; 14. External packaging. DETAILED DESCRIPTION

[0011] The following is a description of the implementation of the present invention by specific embodiments. People familiar with the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0012] In order to enable those skilled in the art to better understand the present application, the present application is further described in detail below in conjunction with the accompanying drawings and specific implementation methods.

[0013] Refer to the attached Figure 1-3, a headlight light emitting diode structure of this embodiment includes a heat dissipation base 1, a ceramic heat dissipation pad 2 is fixedly connected to the heat dissipation base 1, an LED chip 3 is fixedly connected to the ceramic heat dissipation pad 2, a special curved reflector cup 8 is arranged above the LED chip 3, the surface of the special curved reflector cup 8 is plated with a silver-aluminum composite coating, and the "special curved surface" of the special curved reflector cup 8 is a free-form surface obtained by complex ray tracing and optimization calculation based on optical design software (such as Zemax, Code V, etc.). The design goal of the curved surface is to enable the light emitted by the LED chip 3 to propagate in a specific direction after reflection, so as to achieve uniform light distribution and a wide illumination range. In the design process, according to the lighting requirements of the automobile headlights, parameters such as the reflection angle of the light and the brightness distribution of the illumination area are set, and the precise shape of the curved surface is obtained through software optimization. For example, in the low beam mode, the special curved reflector cup can concentrate the light within a certain distance and angle range in front of the vehicle to avoid glare to oncoming vehicles; in the high beam mode, the special curved reflector cup can project the light to a farther distance to expand the illumination range. The silver-aluminum composite coating on its surface has high reflectivity, which can effectively reduce the loss of light during the reflection process and improve lighting efficiency.

[0014] The heat dissipation base 1 is connected with a composite optical lens 9, which is composed of an inner aspheric lens and an outer microprism array lens. The inner aspheric lens is made of optical glass or optical plastic with excellent optical properties and is formed by a special mold. The aspheric design can effectively correct aberrations, reduce the distortion of light during refraction, make the light more focused, and improve the clarity of lighting. The outer microprism array lens is a tiny prism structure made on the outer surface of the lens through precision injection molding or etching technology, and these prisms are arranged in an array. The shape, size and angle of each microprism are carefully designed. According to the principle of light refraction and reflection, the microprism array can perform secondary refracting and reflection on the light, further adjust the propagation direction of the light, enhance the diffusion effect of the light, and make the light distribution in the illumination area more uniform.

[0015] A heat sink 10 is also provided on the ceramic heat sink pad 2. The heat sink fin 10 is wavy and made of high thermal conductivity aluminum alloy. A heat pipe 11 is fixedly embedded in the heat sink fin 10 and both ends of the heat pipe 11 extend out of the heat sink fin 10. One end of the heat pipe 11 is fixedly connected to a heat conductive sheet 12, which is fixedly arranged above the heat sink base 1.

[0016] The heat dissipation base 1 is made of a metal material with high thermal conductivity (such as copper alloy), has a large heat conduction area, can quickly conduct the heat generated by the LED chip 3, and is a key component of the basic support and heat transmission of the entire heat dissipation system. The ceramic heat dissipation pad 2 has good thermal conductivity and electrical insulation. Its low thermal resistance can efficiently transfer the heat generated by the LED chip 3 to the heat dissipation base 1, while avoiding electrical short circuits between the LED chip 3 and the heat dissipation base 1. The wavy heat dissipation fins 10 are made of high thermal conductivity aluminum alloy. The wavy design greatly increases the heat dissipation surface area, which increases the heat dissipation area compared to ordinary flat fins, and can more fully exchange heat with the air. Acetone is filled in the heat pipe 11 as a working medium, and the vaporization and condensation phase change principle of acetone is used to achieve efficient heat transfer. The thermal conductive sheet 12 plays a role in connecting the heat pipe 11 and the heat dissipation base 1, ensuring that the heat can be smoothly transferred from the heat pipe 11 to the heat dissipation base 1, and then dissipated through the heat dissipation fins 10.

[0017] The LED chip electrodes are made of low-resistance metal materials and an optimized energy well structure is adopted inside the LED chip 3. The two ends of the LED chip 3 are fixedly connected with an anode terminal 4 and a cathode terminal 5, respectively. The anode terminal 4 and the cathode terminal 5 are respectively connected with an anode sheet 6 and a cathode sheet 7. The outer side of the composite optical lens 9 is sleeved with an external package 14.

[0018] The specific heat dissipation principle is as follows: the heat generated by the LED chip 3 is first transferred to the ceramic heat dissipation pad 2 in close contact with it. Due to the good thermal conductivity of the ceramic heat dissipation pad 2, the heat is quickly transferred to the heat dissipation base 1. The heat dissipation fins 10 are fixed on the ceramic heat dissipation pad 2 by welding or close fitting, and directly receive the heat from the heat dissipation base 1. The wavy heat dissipation fins 10 increase the contact area with the air, and use natural convection and forced convection (airflow when the car is driving) to dissipate heat. When the car is driving, the external airflow flows through the heat dissipation fins 10 and takes away the heat; when the car is parked, natural convection can also continue to dissipate heat. The acetone in the heat pipe 11 is vaporized by heat, and the vapor quickly diffuses to the area with lower temperature. After being cooled, it condenses into liquid again, releasing the latent heat of vaporization. Through this phase change cycle, the heat is transferred from the heat dissipation fins 10 with higher temperature to the heat conductive sheet 12 with lower temperature, and then transferred from the heat conductive sheet to the heat dissipation base 1, so as to achieve efficient transfer and uniform distribution of heat.

[0019] A headlight LED system includes a headlight LED structure, an intelligent driving circuit, an environment sensing and intelligent control system, and an energy recovery and management system. The intelligent driving circuit is based on digital control, adopts pulse width modulation technology, and integrates overvoltage protection, overcurrent protection, and overheating protection functions. The environment sensing and intelligent control system is equipped with an ambient light sensor, a vehicle speed sensor, and a steering sensor, and can adjust the brightness, lighting range, and lighting angle of the headlight according to the external light intensity, vehicle speed, and steering angle. The energy recovery and management system converts kinetic energy into electrical energy and stores it in a supercapacitor when the vehicle brakes or decelerates, and provides stable electrical energy for the headlight LED structure. The energy recovery and management system has a power management function and can intelligently distribute electrical energy. The supercapacitor is directly connected to the headlight LED structure.

[0020] Intelligent drive circuit assembly: According to the designed circuit schematic, various electronic components such as power transistors, inductors, capacitors and microcontrollers are installed on the printed circuit board PCB. Surface mount technology SMT is used to improve assembly accuracy and reliability. After the circuit welding is completed, preliminary electrical performance tests are carried out to ensure that the circuit works properly.

[0021] The intelligent driving circuit is based on digital control and adopts pulse width modulation (PWM) technology. In the circuit design, a high-performance microcontroller (such as Freescale's MC9S12 series) is selected as the control core to accurately control the duty cycle of the PWM signal, thereby stably adjusting the driving current of the LED. At the same time, in order to enhance the anti-interference ability of the circuit, a π-type filter circuit composed of an inductor, a capacitor and a diode is added to the power input end to effectively suppress the influence of the voltage fluctuation of the automotive electrical system on the driving circuit. In terms of overvoltage protection, when it is detected that the input voltage exceeds the set threshold, the power input is quickly cut off through the control circuit to protect the LED chip 3 and other circuit components; overcurrent protection monitors the driving current in real time through the detection circuit. Once the current exceeds the rated value, the duty cycle of the PWM signal is immediately adjusted to reduce the current to prevent the LED chip 3 from being damaged due to overcurrent; overheat protection is achieved by setting a temperature sensor (such as a thermistor) near the LED chip 3. When the temperature reaches the warning value, the microcontroller reduces the duty cycle of the PWM signal, reduces the power consumption of the LED, and reduces the chip temperature.

[0022] Integration of environmental perception and intelligent control system: Install ambient light sensors, vehicle speed sensors and steering sensors in the corresponding positions of the car to ensure that the sensors can accurately perceive the external environment and vehicle status. Connect the sensor's signal output line to the microcontroller of the intelligent control system, write the corresponding control program, and realize the function of adjusting the LED brightness, lighting range and lighting angle according to the sensor signal.

[0023] Energy recovery and management system installation: In the vehicle's braking energy recovery system, an energy conversion device is connected to convert the kinetic energy generated during braking or deceleration into electrical energy and store it in a supercapacitor. The supercapacitor is connected to the power input port of the headlight LED structure, and a power management chip is installed to achieve intelligent distribution and management of electrical energy.

[0024] When the car brakes or decelerates, the energy recovery and management system converts kinetic energy into electrical energy through the principle of electromagnetic induction. Specifically, an energy conversion device (such as a generator) is installed in the braking system of the car. When the vehicle brakes or decelerates, the rotation of the wheels drives the generator rotor to rotate, cutting the magnetic flux lines to generate electrical energy. The generated electrical energy is stored in a supercapacitor, which has the characteristics of fast charging and discharging speed and long cycle life, and can quickly store and release electrical energy. When providing a stable power supply for the headlight LED structure, the power management chip in the energy recovery and management system (such as Texas Instruments' TPS62740) plays a key role. It can intelligently distribute electrical energy according to the actual power demand of the headlight to avoid wasting electrical energy. In addition, in the system design, the topology of the drive circuit is optimized, and an efficient DC-DC converter is used to improve the conversion efficiency of electrical energy and further reduce the energy consumption of the system.

[0025] Overall system debugging: Connect the manufactured LED structure with various system components to form a complete headlight LED system, and conduct comprehensive performance tests, including heat dissipation performance tests, optical performance tests, electrical performance tests, and intelligent control function tests. Adjustments and optimizations are made based on the test results to ensure that all performance indicators of the system meet the design requirements.

[0026] Finally: The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A headlight light emitting diode structure, characterized in that: The invention comprises a heat dissipation base (1), a ceramic heat dissipation pad (2) being fixedly connected to the heat dissipation base (1), an LED chip (3) being fixedly connected to the ceramic heat dissipation pad (2), a special curved surface reflection cup (8) being arranged above the LED chip (3), the curved surface of the special curved surface reflection cup (8) being obtained by optimizing calculation using a mathematical model and optical design software, the surface of the special curved surface reflection cup (8) being plated with a silver-aluminum composite coating, and a composite optical lens (9) being connected to the outer sleeve of the heat dissipation base (1). The composite optical lens (9) is composed of an inner aspheric lens and an outer microprism array lens; a heat sink fin (10) is also provided on the ceramic heat sink pad (2); the heat sink fin (10) is wavy and made of a high thermal conductivity aluminum alloy; a heat pipe (11) is fixedly embedded in the heat sink fin (10) and both ends of the heat pipe (11) extend out of the heat sink fin (10); one end of the heat pipe (11) is fixedly connected to a heat conductive sheet (12); and the heat conductive sheet (12) is fixedly provided above the heat sink base (1).

2. The headlight light emitting diode structure according to claim 1, characterized in that: The electrodes of the LED chip are made of a low-resistance metal material and an optimized energy well structure is adopted inside the LED chip (3); the two ends of the LED chip (3) are respectively fixedly connected with an anode connection column (4) and a cathode connection column (5); the anode connection column (4) and the cathode connection column (5) are respectively connected with an anode sheet (6) and a cathode sheet (7); the outer side of the composite optical lens (9) is sleeved with an external package (14); and the heat pipe (11) is filled with acetone as a working medium.

3. A headlight light emitting diode system, characterized in that: It comprises a headlight light emitting diode structure as described in any one of claims 1 or 2, as well as an intelligent driving circuit, an environment perception and intelligent control system, and an energy recovery and management system.

4. A headlight LED system according to claim 3, characterized in that: The intelligent driving circuit is based on digital control, adopts pulse width modulation technology, and integrates overvoltage protection, overcurrent protection and overheating protection functions.

5. The headlight LED system according to claim 4, characterized in that: The environmental perception and intelligent control system is equipped with an ambient light sensor, a vehicle speed sensor and a steering sensor, and can adjust the brightness, lighting range and lighting angle of the headlights according to the external light intensity, vehicle speed and steering angle.

6. The headlight LED system according to claim 5, characterized in that: The energy recovery and management system converts kinetic energy into electrical energy when the vehicle brakes or decelerates and stores it in a supercapacitor, and provides stable power to the headlight LED structure.

7. The headlight LED system according to claim 6, characterized in that: The energy recovery and management system has a power management function and can intelligently distribute electrical energy.

8. The headlight LED system according to claim 7, characterized in that: The supercapacitor is directly connected to the headlight light emitting diode structure.

Images