Automobile headlight lamp holder and manufacturing method

Abstract

The present application relates to a lamp holder for automobile headlights and a manufacturing method thereof. The lamp holder is mainly composed of three parts: a metal insert, a reflective component and a lamp holder body. The lamp holder body is provided with a mounting portion, a first plug-in portion and a second plug-in portion. The surfaces of the first plug-in portion and the second plug-in portion are provided with a first sealing layer, which is integrally formed with the lamp holder body by secondary injection molding, avoiding the use of an additional sealing ring. The reflective component is composed of a fixing portion and a reflective portion. The reflective portion includes a base layer, a light reflecting layer and a protective layer, which efficiently reflects light, thereby improving light utilization and lighting effects. The lamp holder also includes a heat dissipation structure, which is composed of heat-absorbing fins and heat-dissipating fins. The heat-absorbing fins fit tightly with the reflective component, shortening the heat conduction path, reducing thermal resistance and improving heat conduction efficiency. The present application also provides a method for manufacturing an automobile headlight lamp holder, including a first injection molding and a second injection molding. By controlling the injection molding process parameters, the high quality and reliability of the lamp holder are ensured.

Description

Technical Field

[0001] The present application relates to the technical field of lamps, and in particular to a lamp holder for an automobile headlight and a manufacturing method thereof. Background Art

[0002] With the rapid development of the automotive industry, automotive headlights, as a crucial component of vehicle safety and aesthetics, are facing increasingly stringent performance requirements. As the key connecting component between the headlight and the vehicle's electrical system, the lamp holder not only provides electrical connectivity but also directly impacts the headlight's sealing, heat dissipation, and overall service life. In recent years, automotive headlight holder technology has made significant progress. By adopting new sealing materials (such as silicone rubber and fluororubber) and optimizing sealing structure designs (such as double-layer sealing rings and labyrinth-style sealing grooves), the lamp holder's waterproof and dustproof performance has been significantly improved, effectively extending the service life of the lamp holder and headlight. Furthermore, to cope with the heat generated by high-power light sources such as LED headlights, lamp holder designs incorporate more efficient heat dissipation mechanisms, such as integrated cooling fins, the use of metal materials with excellent thermal conductivity (such as aluminum alloy), and the use of heat pipes or liquid cooling technology. These improve heat dissipation efficiency and ensure stable operation of the light source. At the same time, with the advancement of materials science, lighter and higher-strength composite materials have begun to be used in lamp holder manufacturing. Through advanced manufacturing processes such as precision injection molding and die-casting, the lightweight and high-precision lamp holder structure has been achieved, which not only reduces manufacturing costs but also improves the overall performance of the product.

[0003] Despite significant progress in automotive headlight socket technology, practical applications still face pressing challenges. While existing sealing technologies meet most application scenarios, extreme environments (such as high temperature, high humidity, and strong winds and sandstorms) can compromise the socket's sealing performance, allowing moisture or dust to intrude and impact headlight operation. Therefore, further improving the socket's sealing reliability has become a key research priority. Furthermore, with the continuous increase in LED headlight power, higher requirements are placed on the socket's heat dissipation performance. However, efficient heat dissipation often comes with increased costs. Maintaining heat dissipation efficiency while effectively controlling manufacturing costs is a major challenge in current lamp socket design. As a long-lasting component of automotive headlights, the lamp socket's durability and ease of maintenance directly impact the user experience. Improving the socket's aging and corrosion resistance while maintaining structural strength, and designing a maintenance structure that facilitates easy disassembly and replacement, are key areas for future lamp socket development. Therefore, research is needed on technical solutions that offer enhanced sealing, improved heat dissipation, lower costs, and improved maintainability. Summary of the Invention

[0004] The purpose of this application is to provide a lamp holder for an automobile headlight, which can further improve the utilization rate of light, and on this basis further optimize the sealing and heat dissipation related structures of the lamp, improve the sealing performance and heat dissipation performance, and ensure the stability and reliability during use. The purpose of this application is achieved through the following technical solutions. The automobile headlight lamp holder of this application includes a metal insert, a reflective component, and a lamp holder body;

[0005] The metal insert is inside the lamp holder body and includes an exposed first connecting end and a second connecting end;

[0006] The lamp holder body includes a mounting portion, a first plug-in portion and a second plug-in portion;

[0007] The reflective component includes a fixing portion and a reflective portion, the reflective portion includes a base layer, a light reflecting layer and a protective layer, and the mounting portion is located at the center of the reflective portion;

[0008] The surfaces of the first plug-in portion and the second plug-in portion include a first sealing layer, and the first sealing layer is formed integrally with the lamp holder body by secondary injection molding.

[0009] In one embodiment, a heat dissipation structure is further included, and the heat dissipation structure includes heat-absorbing fins and heat-dissipating fins, and the heat-absorbing fins are embedded in the injection-molded body of the lamp holder body.

[0010] In one embodiment, the heat absorbing fins are bonded to the reflective component.

[0011] In one embodiment, the light reflecting layer is made of metal material, and the heat absorbing fins are thermally connected to the light reflecting layer.

[0012] In one embodiment, the surface of the metal insert includes convex teeth, and the injection material completely covers the convex teeth during injection molding.

[0013] In one embodiment, the lamp holder body further includes an integrated circuit board, and the metal insert is connected to the integrated circuit board.

[0014] In one embodiment, the first plug-in portion further includes a clamping portion, a second sealing layer is provided on the clamping portion, and the second sealing layer is formed integrally with the clamping portion by secondary injection molding.

[0015] The present application further provides a method for manufacturing a lamp holder for an automobile headlight, comprising the following steps:

[0016] Making the reflective component, including forming the base layer, the light reflecting layer and the protective layer, and cutting and shaping them;

[0017] Clean and preheat the metal inserts;

[0018] Performing a first injection molding to form a lamp holder body that encloses the metal insert and the reflector component fixing portion, wherein the lamp holder body includes a mounting portion, a first plug-in portion, and a second plug-in portion;

[0019] Performing a second injection molding on the lamp holder body to form a first sealing layer on the surfaces of the first plug-in portion and the second plug-in portion;

[0020] The injection temperature of the second injection molding is higher than the injection temperature of the first injection molding, and the temperature is maintained at the second injection molding temperature for more than 10 minutes.

[0021] In one embodiment, the method further includes pre-injection molding the heat dissipation structure before injection molding the lamp holder body.

[0022] In one embodiment, the method further includes connecting the metal insert to the integrated circuit board and pre-injecting the metal insert and the circuit board assembly before injection molding the lamp holder body.

[0023] Compared with the prior art, this application has the following beneficial effects:

[0024] The reflective component in the automotive headlight holder provided by this application adopts a layered structural design, comprising a base layer, a light-reflecting layer, and a protective layer. The light-reflecting layer is made of a high-reflectivity metal material, which effectively reflects light, reduces light scattering and absorption, and improves light utilization, resulting in brighter and more uniform lighting effects for the automotive headlights. By providing a first sealing layer on the surfaces of the first and second plug-in connectors, and a second sealing layer on the clip-on connector, and by integrating these sealing layers with the lamp holder body or the clip-on connector through secondary injection molding, the seal between the lamp holder and the external structure is ensured, effectively preventing impurities such as moisture and dust from entering the lamp holder, thereby extending the service life of the automotive headlights and improving safety in use.

[0025] The heat dissipation structure comprises heat-absorbing fins and heat-dissipating fins. The heat-absorbing fins are embedded in the molded body of the lamp holder and can be bonded to the reflective components (particularly the light-reflecting layer), achieving efficient heat conduction. When the headlights are operating, the heat generated is quickly absorbed by the heat-absorbing fins and dissipated to the surrounding environment through the heat-dissipating fins, effectively reducing the temperature inside the lamp holder, ensuring stable operation of the headlights and preventing performance degradation or damage due to overheating.

[0026] The present invention utilizes a two-shot injection molding process to manufacture automotive headlight sockets. By controlling the injection temperature and holding time, this process ensures a tight bond between the sealing layer and the socket body or the clamping portion, improving the overall quality and reliability of the product. Furthermore, the pre-molded heat dissipation structure and the combination of the metal insert and integrated circuit board further optimize the manufacturing process and enhance production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 is a schematic cross-sectional structural diagram of a lamp holder for an automobile headlight in one embodiment of the present application;

[0028] Figure 2 is a schematic cross-sectional structural diagram of a car headlight holder according to another embodiment of the present application;

[0029] Figure 3 It is a flow chart of the method for manufacturing the automobile headlight holder of the present application.

[0030] Explanation of reference numerals: 100, metal insert; 200, reflective component; 300, lamp holder body; 310, first plug-in portion; 320, second plug-in portion; 400, heat dissipation structure. DETAILED DESCRIPTION

[0031] In order to make the above-mentioned objects, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are described in detail below in conjunction with the accompanying drawings. It will be understood that the specific embodiments described herein are only used to explain the present application, rather than to limit the present application. It should also be noted that, for ease of description, only some, rather than all, structures related to the present application are shown in the accompanying drawings. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0032] As used herein, the terms "comprise," "comprising," and "having," and any variations thereof, are intended to cover non-exclusive inclusions. For example, a process, method, system, product, or apparatus comprising a series of steps or elements is not limited to the listed steps or elements but may optionally include steps or elements not listed, or may optionally include other steps or elements inherent to the process, method, product, or apparatus.

[0033] References herein to "embodiments" mean that a particular feature, structure, or characteristic described in connection with the embodiments may be included in at least one embodiment of the present application. The appearance of this phrase in various places in the specification does not necessarily refer to the same embodiment, nor does it constitute an independent or alternative embodiment that is mutually exclusive of other embodiments. It is understood, both explicitly and implicitly, by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0034] As a key component of vehicle lighting and safety, the design and manufacture of the headlight holder, the core supporting structure of the headlight, directly affects the stability, durability, and lighting performance of the headlight. From a functional perspective, the lamp holder is not only a mechanical carrier for fixing the bulb, but also a conductive hub connecting the vehicle's electrical system and the light source. It must simultaneously meet stringent requirements such as sealing and dustproofing, shock and vibration resistance, and efficient thermal conductivity. The following will focus on the basic structure and manufacturing of the headlight holder. Figures 1 to 2 As shown, the automobile headlight lamp holder in a preferred embodiment of the present application includes a metal insert 100, a reflective component 200, and a lamp holder body 300; the metal insert 100 includes an exposed first connection end and a second connection end in the lamp holder body 300, and the lamp holder body 300 includes a mounting portion, a first plug-in portion 310 and a second plug-in portion 320; the reflective component 200 includes a fixing portion and a reflective portion, and the reflective portion includes a base layer, a light reflecting layer and a protective layer, and the mounting portion is located at the center of the reflective portion, wherein the surfaces of the first plug-in portion 310 and the second plug-in portion 320 include a first sealing layer, and the first sealing layer is formed integrally with the lamp holder body 300 by secondary injection molding.

[0035] The headlight socket of an automobile is primarily composed of three parts: a metal insert 100, a reflective component 200, and a socket body 300. The metal insert 100 is located within the socket body 300 and has exposed first and second connection ends (in actual use, the first and second connection ends may include multiple connection terminals, which are responsible for providing stable power to the bulb). The socket body 300 is designed with a mounting portion, a first plug-in portion 310, and a second plug-in portion 320 to accommodate the installation and connection requirements of different components, allowing for adaptive adjustment based on different signals. The reflective component 200 consists of a fixing portion and a reflective portion. The reflective portion includes a base layer, a light-reflecting layer, and a protective layer, with the mounting portion located in the center. The overall bowl-shaped reflective portion efficiently reflects light from the lamp, effectively preventing light absorption or irregular scattering, thereby improving light utilization and lighting effects. A first sealing layer is provided on the surface of the first plug-in portion 310 and the second plug-in portion 320. The first sealing layer is integrally formed with the lamp holder body 300 by secondary injection molding. This one-piece injection molding method can avoid the use of additional sealing rings, which not only simplifies the installation process and improves the convenience of use, but also enhances the reliability and stability of the seal.

[0036] The metal insert 100 is positioned within the lamp holder body 300, with its connection ends exposed, providing electrical connections. The multiple connection terminals increase power supply flexibility, allowing the lamp holder to accommodate bulbs of varying types and wattages, enhancing its versatility and compatibility. The mounting portion, first plug-in portion 310, and second plug-in portion 320 on the lamp holder body 300 provide locations and interfaces for the installation and connection of other components, ensuring the assembly precision and stability of the entire headlight system. The first sealing layer on the surfaces of the first plug-in portion 310 and the second plug-in portion 320 is integrally formed with the lamp holder body 300 via secondary injection molding, eliminating the need for additional sealing rings and reducing the number of parts and assembly steps. Furthermore, the integrally molded sealing layer offers enhanced sealing performance, effectively preventing foreign matter such as moisture and dust from entering the lamp holder, protecting the electrical connections and bulb from damage. This reduces the failure rate of the lamp holder, lowers repair and replacement costs, and improves vehicle safety and reliability.

[0037] The fixing part of the reflective component 200 enables the reflective component 200 to be stably installed on the lamp holder body 300. The reflective part provides a structural basis for reflecting light. The bowl-shaped design of the reflective part can effectively reflect and focus the light emitted by the lamp. The layered structure of the base layer, the light reflecting layer and the protective layer further optimizes the reflection performance. The light reflecting layer can efficiently reflect light and reduce the loss of light energy. The protective layer can protect the light reflecting layer from erosion and damage from the external environment, thereby extending the service life of the reflective component 200. At the same time, the optimized design of the reflective component 200 also reduces the energy consumption of the headlight.

[0038] The automotive headlight holder also includes a heat dissipation structure 400, consisting of heat-absorbing fins and heat-dissipating fins. The heat-absorbing fins are embedded within the molded body of the lamp holder body 300, positioned closer to the bulb than in conventional lamp holders. This design allows the heat-absorbing fins to be closer to the bulb, facilitating the collection of the large amount of heat generated during operation and achieving more efficient heat collection. After absorbing heat, the heat-absorbing fins quickly transfer the heat to the connected heat-dissipating fins. The heat-dissipating fins, with their large surface area and optimal structural design, dissipate the heat into the surrounding environment, rapidly reducing the temperature of the molded body and ensuring stable operation of the lamp holder body 300 within a suitable temperature range. The heat-absorbing fins, embedded within the molded body of the lamp holder body 300 and positioned closer to the bulb, significantly increase the heat conduction path and contact area between the heat-absorbing fins and the heat source (bulb). According to the principle of heat conduction, a larger contact area means higher heat conduction efficiency. Therefore, the heat-absorbing fins can more quickly and efficiently collect heat generated by the bulb, reducing heat accumulation near the bulb and minimizing the risk of damage from overheating. The efficient heat absorption design enables car headlights to maintain stable performance under long-term high-intensity working conditions, extending the service life of the bulbs, effectively avoiding problems such as brightness decay and burning of the bulbs due to overheating, and improving the reliability and stability of the headlights.

[0039] The heat dissipation fins and the heat absorption fins are integrated to form an efficient heat transfer channel. After the heat absorption fins absorb heat, the heat can be quickly transferred to the heat dissipation fins. The large surface area design of the heat dissipation fins increases the contact area with the surrounding air, accelerating the dissipation of heat. At the same time, the reasonable fin shape and spacing design can promote air flow, form a good convection heat dissipation effect, further improve the heat dissipation efficiency, and quickly reduce the temperature of the injection molded body. The heat absorption fins are embedded in the injection molded body of the lamp holder body 300 to achieve an integrated design of the heat dissipation structure 400 and the lamp holder body 300, making the heat conduction between the heat dissipation structure 400 and the lamp holder body 300 smoother, avoiding the problem of increased thermal resistance due to poor connection, and further improving the heat dissipation efficiency. Structural optimization and integrated design reduce the production cost and maintenance cost of headlights and improve production efficiency.

[0040] The heat-absorbing fins fit tightly against the reflective component 200, particularly when the reflective component 200 is designed in a bowl-shaped structure. This design improves heat conduction efficiency. During headlight operation, heat generated by the bulb is first absorbed by the reflective component 200. Because the reflective component 200 fits tightly against the heat-absorbing fins, heat is quickly and efficiently transferred from the reflective component 200 to the heat-absorbing fins. As the reflector 200 reflects the headlight, it not only efficiently reflects light but also, through excellent heat conduction with the heat-absorbing fins, achieves both improved reflection and heat conduction efficiency through a single component. When the reflective component 200 is bowl-shaped, its interior space better envelops the bulb, making it easier for the reflective component 200 to absorb heat generated by the bulb. The close fit of the heat-absorbing fins against the reflective component 200 significantly shortens the heat conduction path and reduces thermal resistance during the heat conduction process. According to the basic principles of heat conduction, the shorter the heat conduction path and the lower the thermal resistance, the higher the heat conduction efficiency. Therefore, this design can quickly transfer the heat generated by the bulb from the reflective component 200 to the heat-absorbing fins and then dissipate it, effectively reducing the temperature of the reflective component 200 and the surrounding area of ​​the bulb.

[0041] In traditional automotive headlight designs, the reflector component 200 primarily reflects light, while heat dissipation is typically handled by a separate heat dissipation structure 400. In this application, however, the heat-absorbing fins are bonded to the reflector component 200, achieving both improved reflection and heat conduction efficiency through a single component, thus integrating and optimizing functions. This integrated design reduces the number of components, simplifies the overall structure of the headlight, and makes assembly more convenient and quick. The close fit between the reflector component 200 and the heat-absorbing fins ensures a stable temperature environment during headlight operation. This stable temperature environment helps ensure the reflective accuracy of the reflector component 200 and the luminous performance of the bulb, thereby improving the overall lighting effect of the headlight. It also reduces issues such as thermal expansion and contraction of materials caused by temperature fluctuations, reduces the risk of headlight failure, and improves headlight reliability. The above optimization and detailed description of the bonded design between the heat-absorbing fins and the reflector component 200 demonstrates the importance of this design in improving the thermal conduction efficiency of automotive headlights, achieving functional integration and optimization, and enhancing the overall performance and reliability of the headlight.

[0042] The light-reflecting layer is made of a metal material with excellent light-reflecting properties, efficiently reflecting light from the bulb and ensuring excellent lighting performance. Furthermore, the heat-absorbing fins are tightly thermally connected to the light-reflecting layer, creating an excellent heat conduction path between them, allowing heat to be quickly and smoothly transferred from the light-reflecting layer to the heat-absorbing fins. For example, common metal materials such as silver have high reflectivity in the visible light band, reflecting most light in a desired direction. The thermal connection between the heat-absorbing fins and the light-reflecting layer ensures that heat absorbed by the light-reflecting layer is quickly transferred to the heat-absorbing fins. When the bulb is operating, a large amount of heat is generated. While reflecting light, the light-reflecting layer also absorbs some of the heat, causing its own temperature to rise. Due to the excellent thermal conductivity between the heat-absorbing fins and the light-reflecting layer, heat is quickly transferred from the light-reflecting layer to the heat-absorbing fins, where it is then dissipated to the surrounding environment, effectively reducing the temperature of the light-reflecting layer and the surrounding area of ​​the bulb. Rapid heat conduction and heat dissipation can prevent the light reflective layer from being deformed or damaged due to overheating, ensuring the stability of its light reflective performance. Lowering the operating temperature of the bulb can extend the service life of the bulb and reduce the failure and replacement frequency caused by overheating of the bulb. The light reflective layer and the heat-absorbing fins are integrated together through thermal connection to achieve an integrated functional design. The compact structural design is also conducive to saving space and provides more possibilities for the layout of other components of the car.

[0043] Specifically, the metal insert 100 includes raised teeth on its surface. During injection molding, the molded material completely covers the raised teeth. The raised teeth on the metal insert 100 increase the contact area and mechanical engagement between the metal and the molded material. Once the molded material completely covers the raised teeth, during the cooling and solidification process, the molded material and the raised teeth form a nested structure, similar to a mortise and tenon joint, significantly enhancing the bond strength between the metal insert 100 and the molded body. According to mechanical principles, the larger the contact area and the stronger the mechanical engagement, the higher the bond strength. During use, headlight sockets are subject to various forces, such as thermal stress from the bulb's operation and vibration and impact from vehicle travel. Strengthening the bond strength prevents loosening or falling off between the metal insert 100 and the molded body, ensuring the structural stability and reliability of the socket and extending its service life.

[0044] Specifically, the lamp holder body 300 also includes an integrated circuit board (ICB), to which the metal insert 100 is connected. The ICB within the lamp holder body 300 serves as the control hub for the headlight. The metal insert 100 electrically connects to the ICB. The circuit board can be integrated with control modules, including a communication unit and a processing unit. The communication unit is compatible with multiple communication protocols, enabling efficient and stable data exchange with other vehicle electronic systems (such as the body control system and driver assistance system). The processing unit boasts powerful data processing capabilities and rapid response speeds, enabling real-time monitoring and precise control of various headlight operating parameters. It is worth noting that the specific control methods are not fixed but can be flexibly adjusted based on actual needs. Whether adjusting headlight brightness, controlling illumination range, or switching lighting modes for specific scenarios, these can all be easily implemented through software programming. Furthermore, the relevant technology represents a mature computer control system that can utilize a wireless communication module to further optimize the connection between the lamp holder and external devices. Wireless communication minimizes the use of traditional connectors, reduces wiring complexity, and improves system reliability and maintainability. The control module integrated into the integrated circuit board, particularly the processing unit, enables real-time and precise control of various headlight parameters. This adjustable control method makes the headlight system highly flexible. Automakers can customize the headlight control logic based on the positioning of different vehicle models, market demand, and user preferences. For example, this allows for more diverse and personalized lighting effects. By integrating the headlight system with computer systems and leveraging wireless communication technology to achieve interconnection with other vehicle systems, and through data exchange and collaboration with other vehicle electronic systems, the headlight system can be better integrated into the vehicle's overall control architecture, achieving more intelligent functionality.

[0045] A second sealing layer is further provided in the structural design of the clamping portion that secures the lamp holder of a car headlight to components such as the lampshade. This second sealing layer is not simply attached to the surface of the clamping portion, but is instead integrated with the clamping portion through a secondary injection molding process. This secondary injection molding process ensures a tight and secure bond between the second sealing layer and the clamping portion, avoiding problems such as falling off and shifting that may occur with traditional sealing methods. To further enhance the sealing effect, the second sealing layer can further adopt a raised structure with a gradually increasing size from the inside out on the fitting surface. The second sealing layer is formed integrally with the clamping portion through secondary injection molding, eliminating a clear dividing line between the sealing layer and the clamping portion, thus avoiding the sealing failure problems of traditional seals caused by assembly errors, aging, and other reasons. At the same time, the raised structure with a gradually increasing size from the inside out on the fitting surface increases the contact area and sealing pressure between the sealing layer and the sealed surface. When the clamping part is clamped with the lampshade and other components, the raised structure will undergo elastic deformation, filling the tiny gaps and unevenness on the sealed surface, forming multiple sealing lines of defense, effectively preventing the penetration of liquids, gases and other media.

[0046] During use, headlights are exposed to a variety of harsh environmental conditions, such as rain, dust, and car wash fluid. Good sealing prevents these media from entering the headlight interior, protecting the internal electronic and optical components from damage and ensuring proper operation and optical performance. For example, this prevents problems such as bulb short-circuiting and reflector corrosion caused by water ingress, thereby extending the headlight's service life. The overmolding process enables high-precision molding of the secondary sealing layer and the clamping element, ensuring dimensional accuracy and shape consistency. Furthermore, the integrated design allows the clamping element and the secondary sealing layer to be assembled as a single unit, reducing assembly steps and errors. The raised structure also provides guidance and positioning, ensuring smoother and more accurate assembly of the clamping element and the clamped component. Simplifying the structural design and maintenance costs can reduce the manufacturing cost and maintenance difficulty of the headlight. For automakers, this reduces production costs and improves product competitiveness. For consumers, it reduces maintenance costs and improves the cost-effectiveness of vehicle use. Furthermore, the simplified structure facilitates the recycling and reuse of the headlights.

[0047] The present application further provides a method for manufacturing a lamp holder for an automobile headlight, comprising the following steps: making a reflective component 200, including forming a base layer, a light reflecting layer and a protective layer, cutting and shaping the reflective component 200, cleaning and preheating the metal insert 100, performing a first injection molding, and forming a lamp holder body 300 that wraps the metal insert 100 and the fixing part of the reflective component 200, wherein the lamp holder body 300 includes a mounting portion, a first plug-in portion 310 and a second plug-in portion 320, performing a second injection molding on the lamp holder body 300, and forming a first sealing layer on the surface of the first plug-in portion 310 and the second plug-in portion 320, wherein the injection molding temperature of the second injection molding is higher than the injection molding temperature of the first injection molding, and the heat is maintained at the second injection molding temperature for more than 10 minutes.

[0048] First, the composition, thickness, and uniformity of each layer of material are controlled. The base layer is made of a material with good mechanical properties and thermal stability to provide a solid support for the subsequent light-reflecting layer and protective layer. The light-reflecting layer is made of a metal or alloy material with high reflectivity. Through vacuum coating, electroplating and other processes, it is ensured to have extremely high light reflection efficiency to maximize the reflection of light and improve the lighting effect of the headlights. The protective layer is made of corrosion-resistant and wear-resistant materials, such as organic coatings or inorganic coatings, to fully protect the light-reflecting layer and prevent it from being damaged during subsequent processing and use. The reflective component 200 is precisely cut. During the cutting process, the cutting size accuracy and shape error are controlled, and the cut edges are deburred to improve the surface quality and assembly accuracy of the reflective component 200. The final shape can be formed into a bowl shape according to the choice of bulb.

[0049] The metal insert 100 is cleaned to remove impurities such as oil, dust, and oxides from its surface. During the cleaning process, appropriate cleaning process parameters are selected based on the material and surface condition of the metal insert 100 to ensure optimal cleaning results. The metal insert 100 has a certain shape. The cleaned metal insert 100 is placed in a preheating device for preheating. The preheating temperature is precisely controlled based on the material of the metal insert 100 and the requirements of the subsequent injection molding process. Preheating can evenly increase the temperature of the metal insert 100, reduce the temperature difference between the metal insert 100 and the injection molding material, improve the fluidity and filling performance of the injection molding material, and thus ensure the bonding strength between the metal insert 100 and the injection molding material.

[0050] Depending on actual needs, the surface of the metal insert 100 can be roughened or pores can be formed. Roughening can be achieved through methods such as sandblasting and chemical etching to increase the surface roughness of the metal insert 100, thereby improving the mechanical engagement and bonding area between the injection molding material and the metal insert 100. Holes can be formed through processes such as drilling and punching, creating a certain number and distribution of holes on the surface of the metal insert 100, allowing the injection molding material to penetrate into the holes and form a more secure mechanical interlocking structure.

[0051] During the first injection molding process, a suitable injection molding material is selected, and the molten plastic is injected into the mold by an injection molding machine to form the lamp holder body 300 that encapsulates the metal insert 100 and the fixing part of the reflective component 200. During the injection molding process, process parameters such as injection temperature, pressure, and speed are controlled to ensure that the plastic can fully fill the mold cavity and form a lamp holder body 300 with accurate shape and high dimensional accuracy. The lamp holder body 300 includes key structures such as the mounting portion, the first plug-in portion 310, and the second plug-in portion 320. The mounting portion is used to install the lamp holder body 300 in a fixed position on the car headlight, and its shape and size are designed according to the installation requirements of the car headlight. The first plug-in portion 310 and the second plug-in portion 320 are used to plug and match with other components to achieve electrical and mechanical connection. During the injection molding process, the shape and dimensional accuracy of these structures are ensured to meet the design requirements through mold design and injection molding process control.

[0052] A second injection molding process is performed on the lamp holder body 300 formed by the first injection molding process. The second injection molding temperature is higher than the first injection molding temperature, and the material is held at the second injection molding temperature for at least 10 minutes. The higher injection molding temperature improves the fluidity and filling properties of the injection molding material, allowing it to better fill the fine structures and gaps in the lamp holder body 300 formed by the first injection molding process. Holding the material at the second injection molding temperature for at least 10 minutes allows the cross-section of the first and second injection molding materials to fuse, improving the joint strength.

[0053] Through the second injection molding, a first sealing layer is formed on the surfaces of the first plug-in portion 310 and the second plug-in portion 320. The first sealing layer is made of a material with excellent sealing properties, which can effectively prevent moisture, dust and other media from entering the plug-in portion, ensuring the reliability and stability of the electrical connection. Due to the use of temperature and heat insulation control, the bonding strength is even higher.

[0054] By precisely controlling the materials and processes for the base layer, light-reflecting layer, and protective layer, the reflective component 200 exhibits excellent properties such as high reflectivity, corrosion resistance, and wear resistance. The high-reflectivity light-reflecting layer reflects more light, improving the brightness and uniformity of the headlight. The protective layer protects the light-reflecting layer from environmental erosion and damage, extending the service life of the reflective component 200. Cleaning, preheating, and surface treatment of the metal insert 100 enhance the bond strength between the metal insert 100 and the injection molding material. Cleaning removes impurities from the metal insert 100's surface and improves wettability between the injection molding material and the metal insert 100.

[0055] During the first injection molding process, controlled injection molding process parameters and mold design ensure that the lamp holder body 300 exhibits precise shape and high dimensional accuracy. The dimensional accuracy and shape stability of the mounting portion, first plug-in portion 310, and second plug-in portion 320 are effectively guaranteed, meeting the assembly requirements of automotive headlights. The first sealing layer formed during the second injection molding process offers excellent sealing properties, effectively preventing moisture, dust, and other media from entering the plug-in portion. The higher injection temperature and holding time further fuse the injection molding materials, resulting in a stronger sealing layer.

[0056] Specifically, it also includes the step of pre-injecting the heat dissipation structure 400 before injection molding the lamp holder body 300. The heat dissipation structure 400 is pre-injected before the lamp holder body 300 is formally injection molded. The pre-injection molding uses different injection molding conditions from the lamp holder body 300, such as adjusting the injection molding temperature, pressure, speed and other parameters, so that the injection molding body of the heat dissipation structure 400 can complete the injection molding process independently. After the pre-injection molding is completed, the heat dissipation structure 400 is subjected to a comprehensive inspection. The inspection content includes dimensional accuracy, appearance quality, structural integrity and other aspects. Through a single inspection, defects that may occur in the heat dissipation structure 400 during the injection molding process, such as shrinkage holes, bubbles, deformation, etc., can be discovered in time, and corresponding measures can be taken to correct or scrap them, so as to avoid bringing the defective heat dissipation structure 400 into the subsequent integral injection molding process with the lamp holder body 300, thereby effectively improving the overall quality of the product.

[0057] Before the lamp holder body 300 is injection molded, a pre-molding step is performed on the metal insert 100 and the integrated circuit board to establish an electrical and mechanical connection between the integrated circuit board and the metal insert 100. First, specific locations on the metal insert 100 are metallized with treatments such as gold or nickel plating to improve solderability and electrical connection reliability. Then, a reflow process precisely welds the pads on the integrated circuit board to the metallized areas on the metal insert 100. During the reflow process, the soldering temperature profile is strictly controlled to ensure optimal solder joint quality and avoid defects such as cold solder joints and short circuits.

[0058] The integrated circuit board integrates a control module, which consists of a communication unit and a processing unit. The communication unit is responsible for exchanging data with the vehicle's other electronic systems to implement intelligent headlight control functions, such as automatically adjusting headlight brightness based on ambient light intensity and switching between high and low beams based on the vehicle's driving status. The processing unit processes and analyzes the signals received by the communication unit and generates corresponding control instructions based on a preset algorithm to control the headlight's operating status.

[0059] A specialized pre-injection mold is designed based on the shape and dimensions of the metal insert 100 and integrated circuit board assembly. The mold is constructed from high-strength, high-precision materials to ensure excellent dimensional stability during the injection molding process. The shape and dimensions of the mold cavity closely match the assembly to guarantee the shape and dimensional accuracy of the pre-molded product. Injection molding materials with excellent electrical insulation, mechanical properties, and thermal stability, such as polyphenylene sulfide (PPS) and liquid crystal polymer (LCP), are selected. These materials not only meet the performance requirements of the pre-molded product but also exhibit good compatibility with the material of the subsequent lamp holder body 300, ensuring a strong bond between the two.

[0060] During the pre-injection molding process, process parameters such as injection temperature, pressure, and speed are precisely controlled. The injection temperature is set according to the characteristics of the selected injection molding material to ensure that the material can be fully melted and has good fluidity. The injection pressure and speed are adjusted according to the shape and size of the assembly to ensure that the material can evenly fill the mold cavity and avoid defects such as bubbles and shrinkage holes. After the pre-injection molding is completed, the pre-injection molded product is visually inspected to check whether there are defects such as bubbles, cracks, and deformation on the product surface. Products with unqualified appearance are marked and rejected in a timely manner. Professional electrical testing equipment is used to conduct electrical performance testing on the integrated circuit boards in the pre-injection molded products, including communication function testing and control function testing. Ensure that the communication unit can normally exchange data with external devices and that the processing unit can correctly process signals and generate control instructions. Products with unqualified electrical performance are reworked or scrapped.

[0061] The pre-injection molding process encases the metal insert 100 and integrated circuit board in a molded material, forming a single, integrated structure. The molded material possesses excellent mechanical properties, providing effective support and protection for the assembly and enhancing structural stability. Furthermore, the precise design of the pre-injection mold ensures the precise shape and dimensional accuracy of the pre-injected product, ensuring a perfect fit with the subsequent injection-molded lamp holder 300. This prevents loosening and displacement of the metal insert 100 and integrated circuit board during driving, thereby improving the overall quality and reliability of the headlamp. Furthermore, the pre-injection molding process reduces defects during co-molding, thereby increasing production efficiency.

[0062] As can be seen from the foregoing, the present application aims to provide an automotive headlight holder and manufacturing method to improve the overall performance, reliability, and production efficiency of the headlight. The holder primarily consists of three major components: a metal insert, a reflector, and a main body. Located within the main body, it features exposed first and second connection terminals (which may include multiple terminals for providing stable power to the bulb). The main body has serrations, which are completely covered by the injection molding material during injection molding, enhancing bonding strength and ensuring structural stability and reliability. The main body comprises a mounting portion, a first plug-in portion, and a second plug-in portion, providing mounting and connection locations and interfaces for other components. The first and second plug-in portions are coated with a first sealing layer and are integrally formed with the main body via a secondary injection molding process. This eliminates the need for additional sealing rings, simplifies the installation process, and enhances sealing reliability and stability. The main body also houses an integrated circuit board (ICB), connected to the metal insert. The PCB integrates a control module (including a communication unit, processing unit, etc.), enabling flexible control adjustments and implementing intelligent functions.

[0063] The reflector assembly consists of a fixed portion and a reflector portion. The reflector portion includes a base layer, a light-reflecting layer, and a protective layer. The mounting portion is located in the center of the reflector. The overall bowl-shaped design efficiently reflects light, improving light utilization and lighting effects. The light-reflecting layer is made of a metal material (such as silver) with excellent light-reflecting properties. The heat-absorbing fins are tightly connected to it, forming an excellent heat conduction path for rapid heat dissipation, preventing deformation or damage to the light-reflecting layer and extending the life of the bulb.

[0064] The heat dissipation structure consists of heat-absorbing fins and heat-dissipating fins. The heat-absorbing fins are embedded in the molded body of the lamp holder and located close to the bulb, rapidly collecting heat and transferring it to the heat-dissipating fins. The large surface area and strategic design of the heat-dissipating fins accelerate heat dissipation, lowering the temperature of the molded body. The heat-absorbing fins fit snugly against the reflective component, shortening the heat conduction path, reducing thermal resistance, and improving heat transfer efficiency. This achieves a dual improvement in both reflection and heat transfer efficiency, optimizing functional integration, reducing the number of components, simplifying the structure, improving assembly efficiency, and reducing the risk of failure.

[0065] A second sealing layer is provided at the clamping part and is integrated with the clamping part through a secondary injection molding process. The fitting surface adopts a raised structure with gradually increasing size from the inside to the outside, which increases the contact area and sealing pressure, forms multiple sealing lines of defense, effectively prevents medium penetration, protects internal components and optical parts, and reduces manufacturing costs and maintenance difficulty.

[0066] The automobile headlight holder and manufacturing method of the present application effectively improve the performance, reliability and production efficiency of automobile headlights by optimizing structural design and adopting advanced manufacturing processes and materials.

[0067] The above is only a specific implementation of the present application. Any other improvements made based on the concept of the present application are considered to be within the scope of protection of the present application.

Claims

1. A car headlight lamp holder, characterized in that: Including metal inserts, reflective components, and lamp holder body; The metal insert is in the lamp holder body, and the lamp holder body wraps the metal insert, including an exposed first connection end and a second connection end; The lamp holder body includes a mounting portion, a first plug-in portion and a second plug-in portion; The reflective component includes a fixing portion and a reflective portion, the reflective portion includes a base layer, a light reflecting layer and a protective layer, the mounting portion is located at the center of the reflective portion, and the protective layer protects the light reflecting layer; Wherein, the surfaces of the first plug-in portion and the second plug-in portion include a first sealing layer, and the first sealing layer is formed integrally with the lamp holder body by secondary injection molding; It also includes a heat dissipation structure, which includes heat-absorbing fins and heat-dissipating fins, and the heat-dissipating fins and the heat-absorbing fins are integrally arranged; the light-reflecting layer is made of metal material, the heat-absorbing fins are tightly fitted to the reflective component, and the heat-absorbing fins are directly thermally connected to the light-reflecting layer; The heat absorbing fins are embedded in the injection molded body of the lamp holder body; The first plug-in portion further includes a clamping portion, a second sealing layer is provided on the clamping portion, and the second sealing layer is formed integrally with the clamping portion by secondary injection molding.

2. The automobile headlight holder according to claim 1, characterized in that: The surface of the metal insert comprises convex teeth, and the injection material completely covers the convex teeth during injection molding.

3. The automobile headlight holder according to claim 1, characterized in that: The lamp holder body also includes an integrated circuit board, and the metal insert is connected to the integrated circuit board.

4. A method for manufacturing an automobile headlight socket, comprising manufacturing the automobile headlight socket according to any one of claims 1 to 3, characterized in that: The steps include: Making the reflective component, including forming the base layer, the light reflecting layer and the protective layer, and cutting and shaping them; Clean and preheat the metal inserts; Performing a first injection molding to form a lamp holder body that encloses the metal insert and the reflector component fixing portion, wherein the lamp holder body includes a mounting portion, a first plug-in portion, and a second plug-in portion; Performing a second injection molding on the lamp holder body to form a first sealing layer on the surfaces of the first plug-in portion and the second plug-in portion; The injection temperature of the second injection molding is higher than that of the first injection molding, and the temperature is kept at the second injection molding temperature for more than 10 minutes; The heat absorbing fins of the heat dissipation structure are embedded in the injection molded body of the lamp holder body by injection molding, and the heat absorbing fins are closely fitted to the reflective component, and the heat absorbing fins are directly connected to the light reflective layer in a heat-conducting manner.

5. The method for manufacturing a lamp holder for an automobile headlight according to claim 4, wherein: The method further includes the step of pre-injecting the heat dissipation structure before injection molding the lamp holder body.

6. The method for manufacturing a lamp holder for an automobile headlight according to claim 4, wherein: The method also includes the steps of connecting the metal insert with the integrated circuit board and pre-injecting the combination of the metal insert and the circuit board before injection molding to form the lamp holder body.

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