Composite light distribution module and manufacturing method thereof

Abstract

The invention provides a combined type light distribution module and a manufacturing method thereof. The combined type light distribution module comprises a substrate, a lens, a lamp bead, a wire rod and a shell. A lamp bead and a lens are arranged on the upper surface of the substrate, the lamp bead is located in the lens, the substrate is provided with a silk-screen layer, and the silk-screen layer surrounds the joint of the lens and the substrate; the wire rods are connected to the two ends of the substrate respectively; the shell is provided with a containing space, a first opening and a second opening, the substrate is arranged in the containing space, the protruding portion of the lens is arranged at the first opening, and the wire penetrates through the second opening. The LED lamp has the advantages of being high in lighting effect utilization rate, simple in structure, low in cost, good in adjusting flexibility, small in occupied space and high in light utilization rate.

Description

Technical Field

[0001] The present invention relates to the technical field of optical lighting, and in particular to a composite light distribution module and a manufacturing method thereof. Background Art

[0002] With the development of society and economy, the demand for advertising light boxes is increasing, and the requirements for advertising light boxes are also getting higher and higher. Traditional light distribution modules have problems such as a single light distribution mode and low light efficiency utilization, which makes it difficult to meet the diversified needs of light boxes, such as the gradual thinning of light boxes. Although some existing technologies have improved, they are complex in structure, high in cost, and lack adjustment flexibility. The thickness of existing advertising light boxes on the market is basically over 6CM thick. The product application cost is high, the space is large, and the light box is densely packed. There are also problems such as reflection through TV backlight solutions (low light utilization and high requirements for reflective surfaces) and light guide plate solutions (light guide plates are too heavy). Summary of the Invention

[0003] The purpose of the present invention is to provide a composite light distribution module and a manufacturing method thereof, so as to solve the problems in the prior art of single light distribution mode, low light efficiency utilization, complex structure, high cost and insufficient adjustment flexibility, high product application cost, large space occupation and low light utilization.

[0004] In one aspect, the present invention provides a composite light distribution module, comprising a substrate, a lens, a lamp bead, a wire and a housing; A lamp bead and a lens are provided on the upper surface of the substrate, the lamp bead is located in the lens, and the substrate has a silk screen layer, which surrounds the connection between the lens and the substrate; The wires are respectively connected to both ends of the substrate; The housing has a receiving space and is provided with a first opening and a second opening. The substrate is arranged in the receiving space. The raised portion of the lens is arranged at the first opening. The wire is passed through the second opening.

[0005] The connection between the lens and the substrate is circular, the lamp bead is located at the center of the circle, and the silk-screen layer is provided in an area surrounding the circle.

[0006] The silk-screen layer is a black silk-screen layer.

[0007] The thickness of the silk-screen layer ranges from 10 to 25 μm, and the thickness of the silk-screen layer gradually increases from the edge of the lens to the outside.

[0008] In one aspect, a method for manufacturing a composite light distribution module is provided, comprising: The lamp beads and the lens are arranged on the upper surface of the substrate, the lamp beads are arranged in the lens, and the silk screen layer surrounds the connection between the lens and the substrate; wherein the substrate has the silk screen layer; Connect the wires to both ends of the substrate; The substrate is arranged in the accommodation space, the protrusion of the lens is arranged at the first opening, and the wire is passed through the second opening; wherein the housing has an accommodation space and is provided with the first opening and the second opening.

[0009] Also includes: A black silk screen layer is produced; the silk screen layer is a black silk screen layer.

[0010] The method of making the black silk screen layer includes: Preheat the acrylate in the ink to 50-60°C to reduce the resin viscosity; Treating carbon black with a silane coupling agent to modify the pigment; Mix the acrylate, solvent, and dispersant and stir at 800-1000 rpm for 10-15 minutes; Add carbon black in portions and stir at 1000-1200 rpm for 20-25 minutes; Use a sand mill to grind the powder to a fineness of 5-15 μm or less; After grinding, add functional additives and mix at 800-900 rpm for 15-20 minutes; Use solvent to dilute the viscosity of the silk screen layer; Use a filter to remove particulate matter.

[0011] The ink is one of copper foil substrate matte ink, high hiding UV ink, environmentally friendly water-based ink, and insulating ink.

[0012] Also includes: The lamp bead is arranged at the center of the connection between the lens and the substrate, and the silk-screen layer is arranged in the area surrounding the connection between the lens and the substrate; wherein the connection between the lens and the substrate is circular.

[0013] Also includes: The thickness of the silk-screen layer gradually increases from the edge of the lens to the outside, and the thickness of the silk-screen layer ranges from 10 to 25 μm.

[0014] As described above, the composite light distribution module and the manufacturing method thereof of the present invention have the following beneficial effects: The light efficiency is high, the structure is simple, the cost is low, the adjustment flexibility is good, the space occupied is small, and the light utilization rate is high. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1An exploded diagram of the structure of a composite light distribution module provided in one embodiment of the present invention; Figure 2 A schematic structural diagram of a composite light distribution module provided by one embodiment of the present invention. DETAILED DESCRIPTION

[0016] The following describes the embodiments of the present invention through specific examples. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments. The details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the following embodiments and features in the embodiments can be combined with each other unless they conflict.

[0017] It should be noted that the illustrations provided in the following embodiments are merely schematic illustrations of the basic concept of the present invention. Therefore, the illustrations only show components related to the present invention and are not drawn according to the number, shape, and size of components in actual implementation. In actual implementation, the type, quantity, and proportion of each component may be changed arbitrarily, and the component layout may also be more complex.

[0018] It should be noted that the structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification for understanding and reading by those familiar with this technology, and are not used to limit the conditions for implementation of the present invention. Therefore, they have no substantial technical significance. Any modification of the structure, change in the proportional relationship, or adjustment of the size should still fall within the scope of the technical content disclosed by the present invention without affecting the efficacy and purpose that can be achieved by the present invention. At the same time, the terms such as "upper", "lower", "left", "right", "middle" and "one" quoted in this specification are only for the convenience of description and are not used to limit the scope of implementation of the present invention. Changes or adjustments in their relative relationships should also be regarded as the scope of implementation of the present invention without substantially changing the technical content.

[0019] See also Figure 1-Figure 2 , Figure 1 This is an exploded diagram of the structure of a composite light distribution module provided by one embodiment of the present invention. Figure 2A structural schematic diagram of a composite light distribution module provided for one embodiment of the present invention, a composite light distribution module in this case includes a substrate 1, a lens 2, a lamp bead 3, a wire 4 and a shell 5; the upper surface of the substrate 1 is provided with a lamp bead 3 and a lens 2, the lamp bead 3 is located in the lens 2, the substrate 1 has a silk screen layer 11, and the silk screen layer 11 surrounds the connection between the lens 2 and the substrate 1; the wire 4 is respectively connected to the two ends of the substrate 1; the shell 5 has a accommodating space and is provided with a first opening 51 and a second opening 52, the substrate 1 is arranged in the accommodating space, the raised portion of the lens 2 is arranged at the first opening 51, and the wire 4 is passed through the second opening 52.

[0020] In this embodiment, the composite light distribution module integrates multiple light distribution components through innovative structural design to achieve different light distribution and intensity adjustment. The module includes core components such as two basic lens groups, LED chip arrangement, and PCB board white reflective ink matching design. This allows for adjustment of light diffusion. The various components work together to adapt to different usage scenarios, significantly improving light efficiency utilization and light distribution accuracy. By combining the optical lens 2 and the PCB surface treatment with three optical fine adjustments, the composite module can be applied to ultra-thin light boxes, reducing the number of lighting layouts and achieving uniform and high-efficiency solutions.

[0021] The connection between the lens 2 and the substrate 1 is circular, the lamp bead 3 is located at the center of the circle, and the silk screen layer 11 is provided in the area surrounding the circle. The silk screen layer 11 is a black silk screen layer 11.

[0022] In this embodiment, the black silk-screened area is precisely planned based on the shape, size, and optical requirements of the lens 2. For a circular lens 2, the silk-screened area is typically designed as a concentric ring surrounding the lens 2; the lens 2 can also be configured as a rectangle, and for a rectangular lens 2, a rectangular frame is used. The width of the silk-screened area must take into account factors such as the effective aperture of the lens 2, the incident angle of the light, and the light absorption capacity of the silk-screen layer 11. Generally speaking, the width of the silk-screened area should be wide enough to cover the area around the lens 2 where reflections may occur, but it should not be too wide to affect the layout and electrical performance of other components on the PCB. In addition, the assembly error between the lens 2 and the PCB must be considered, and a certain margin must be reserved to ensure that the black silk-screen can effectively reduce the reflection of the lens 2 under various assembly conditions.

[0023] The thickness of the silk-screen layer 11 is in the range of 10-25 μm, and the thickness of the silk-screen layer 11 gradually increases from the edge of the lens 2 toward the outside.

[0024] In this embodiment, the thickness of the black silk-screen layer 11 is closely related to its light absorption performance. Generally speaking, a standard black silk-screen thickness (10-25 μm) is sufficient for light shielding. As the thickness of the silk-screen layer 11 increases, its light absorption capacity increases, and the reflection reduction effect becomes more pronounced. However, an excessively thick silk-screen layer 11 will prolong the ink drying time, increasing production cycle time and costs. It may also result in printing defects such as ink flow and irregular edges, affecting the appearance and performance of the PCB board. Therefore, it is necessary to determine the appropriate thickness of the silk-screen layer 11 through experimentation and process optimization, balancing production efficiency and product quality while ensuring light absorption performance. To further enhance the reflection reduction effect, the black silk-screen pattern can be optimized. For example, using microstructured patterns, such as nanoscale grooves or protrusions, can alter the light propagation path, increasing light scattering and absorption within the silk-screen layer 11. Alternatively, a gradient silk-screen pattern can be designed, where the color or thickness of the silk-screen layer 11 gradually changes from the edge of the lens 2 toward the outside, to better adapt to light incident at different angles and improve overall light absorption efficiency. When designing the silkscreen pattern, optical simulation software should be used to analyze and predict the impact of different patterns on the reflection reduction effect, allowing the optimal design to be selected. Furthermore, the black silkscreen design must be compatible with other designs on the PCB, such as the circuit routing and component layout. Avoid overlapping critical electrical connections, pads, and components in the silkscreen area to prevent impacting the PCB's electrical performance and assembly process. Furthermore, the compatibility of the silkscreen layer 11 with the PCB's surface coating (such as solder mask) must be considered to ensure chemical reactions or poor adhesion between the two. During the design phase, communication and collaboration with PCB design engineers should be strengthened, comprehensively considering both optical and electrical performance requirements to optimize the overall PCB design.

[0025] This composite light distribution module lighting technology not only solves the problems of existing technologies and meets the development needs of the advertising industry, but also helps further achieve more efficient, energy-saving, and environmentally friendly advertising lighting. It is committed to perfectly combining a high-brightness LED light source with a composite optical wide-angle lens, fundamentally improving product efficiency, brightness, beam angle, and reliability, while reducing failure rates and installation and maintenance costs.

[0026] A method for manufacturing a composite light distribution module in this case includes steps S1-S3: S1. Arrange the lamp bead 3 and the lens 2 on the upper surface of the substrate 1. The lamp bead 3 is arranged in the lens 2. The silk screen layer 11 surrounds the connection between the lens 2 and the substrate 1. The substrate 1 has the silk screen layer 11.

[0027] S2. Connect the wires 4 to both ends of the substrate 1 respectively.

[0028] S3. Place the substrate 1 in the accommodation space, place the raised portion of the lens 2 at the first opening 51 , and pass the wire 4 through the second opening 52 ; wherein the housing 5 has an accommodation space and is provided with the first opening 51 and the second opening 52 .

[0029] The composite light distribution module fabricated using this case's method integrates multiple light distribution components through innovative structural design, achieving variable light distribution and intensity adjustment. The module includes core components such as two basic lens sets, LED chip arrangement, and a PCB board with matching white reflective ink. This allows for adjustable light diffusion. These components work together to adapt to different usage scenarios, significantly improving light efficiency and light distribution accuracy. By combining the optical lens 2 with the PCB surface treatment through three optical adjustments, the module can be integrated into ultra-thin light boxes, reducing the number of lights required and ensuring uniform, high-efficiency lighting.

[0030] When using a black silkscreen layer in the light-emitting module area, the design goal is the opposite of conventional silkscreen: it needs to prevent light leakage (for example, hiding the LED structure when unlit), while also potentially achieving a specific lighting effect when lit (such as uniform backlighting). However, black silkscreen itself has very low light transmittance, so achieving light emission underneath requires special design to address this issue. See the following steps for details.

[0031] Preferably, the manufacturing method of a composite light distribution module in this case further includes steps S4-S6: S4, making a black silk screen layer 11; the silk screen layer 11 is a black silk screen layer 11. Step S4 includes steps S41-S48: S41. Preheating the acrylate in the ink to 50-60° C. to reduce the resin viscosity; the ink is one of copper foil base matte ink, high hiding UV (ultraviolet curing) ink, environmentally friendly water-based ink, and insulating ink.

[0032] In this embodiment, the resin or binder can be one of polyurethane acrylate, epoxy resin, saturated polyester resin, and silicone resin. Polyurethane acrylate is selected in this case.

[0033] S42. Treat carbon black with a silane coupling agent (such as KH-550) to modify the pigment.

[0034] In this example, carbon black (particle size 15-30 μm, with different particle sizes required) is used as the pigment. The pigment is modified to improve dispersibility. Carbon black blending involves coarse particles (25-30 μm) providing structural coverage, while fine particles (15-20 μm) fill the gaps. Particle size blending can improve hiding efficiency (e.g., a 2:1 ratio of 25-30 μm to 15-20 μm).

[0035] S43. Mix the acrylate, solvent, and dispersant, and stir at a speed of 800-1000 rpm for 10-15 minutes.

[0036] In this embodiment, the solvent or active monomer may be PMA (propylene glycol methyl ether acetate) or HDDA (hexanediol diacrylate), and the dispersant may be BYK-163.

[0037] S44. Add carbon black in portions and stir at a speed of 1000-1200 rpm for 20-25 minutes.

[0038] In this embodiment, pigment is added and dispersed at high speed until it is initially uniform.

[0039] S45. Use a sand mill to grind the powder in a cycle until the fineness is less than or equal to 5-15 μm.

[0040] In this embodiment, a sand mill is used for cyclic grinding to a fineness of ≤15 μm (a higher requirement is ≤5 μm). For example, copper foil ink requires 4 rounds of sand grinding for refinement.

[0041] S46. After grinding, add functional additives and mix at a speed of 800-900 rpm for 15-20 minutes.

[0042] In this embodiment, functional additives (matting powder, wax powder, and leveling agent) were added after grinding, and mixed at a low speed (800 rpm, 15-20 minutes) to avoid the introduction of bubbles.

[0043] S47 , diluting the viscosity of the silk-screen layer 11 with a solvent.

[0044] In this embodiment, the viscosity is controlled by diluting the solution with a solvent to a viscosity suitable for screen printing (4000-12000 centipoise).

[0045] S48. Use a filter to remove particulate matter.

[0046] In this embodiment, the particles are removed by filtering through a 5-10 μm filter.

[0047] In summary, black screen printing ink primarily consists of pigments, resins, solvents, and functional additives. Pigments are key components in determining the ink's light absorption properties. Common black pigments, such as carbon black, have a direct impact on the ink's light absorption efficiency due to their particle size, structure, morphology, and dispersibility. Carbon black with smaller and more evenly dispersed particles absorbs light more effectively and reduces reflection. The type and properties of the resin, the film-forming substance of the ink, influence the adhesion, abrasion resistance, and chemical resistance of the screen printing layer 11. A suitable resin ensures that the black screen printing layer 11 adheres firmly to the PCB and maintains stable optical properties during subsequent processing and use. Solvents influence the ink's viscosity and drying speed. A suitable solvent formulation helps achieve a uniform screen printing effect. Functional additives, such as defoamers and leveling agents, can improve the ink's printability, reduce printing defects, and ensure a smooth surface for the screen printing layer 11, thereby enhancing light absorption.

[0048] S5. Arrange the lamp bead 3 at the center of the connection between the lens 2 and the substrate 1, and arrange the silk-screen layer 11 around the connection between the lens 2 and the substrate 1; wherein the connection between the lens 2 and the substrate 1 is circular.

[0049] In this embodiment, the black silk-screened area is precisely planned based on the shape, size, and optical requirements of the lens 2. For a circular lens 2, the silk-screened area is typically designed as a concentric ring surrounding the lens 2; the lens 2 can also be configured as a rectangle, and for a rectangular lens 2, a rectangular frame is used. The width of the silk-screened area must take into account factors such as the effective aperture of the lens 2, the incident angle of the light, and the light absorption capacity of the silk-screen layer 11. Generally speaking, the width of the silk-screened area should be wide enough to cover the area around the lens 2 where reflections may occur, but it should not be too wide to affect the layout and electrical performance of other components on the PCB. In addition, the assembly error between the lens 2 and the PCB must be considered, and a certain margin must be reserved to ensure that the black silk-screen can effectively reduce the reflection of the lens 2 under various assembly conditions.

[0050] S6. The thickness of the silk-screen layer 11 gradually increases from the edge of the lens 2 toward the outside, and the thickness of the silk-screen layer 11 ranges from 10 to 25 μm.

[0051] In this embodiment, the thickness of the black silk-screen layer 11 is closely related to its light absorption performance. Generally speaking, a standard black silk-screen thickness (10-25 μm) is sufficient for light shielding. As the thickness of the silk-screen layer 11 increases, its light absorption capacity increases, and the reflection reduction effect becomes more pronounced. However, an excessively thick silk-screen layer 11 will prolong the ink drying time, increasing production cycle time and costs. It may also result in printing defects such as ink flow and irregular edges, affecting the appearance and performance of the PCB board. Therefore, it is necessary to determine the appropriate thickness of the silk-screen layer 11 through experimentation and process optimization, balancing production efficiency and product quality while ensuring light absorption performance. To further enhance the reflection reduction effect, the black silk-screen pattern can be optimized. For example, using microstructured patterns, such as nanoscale grooves or protrusions, can alter the light propagation path, increasing light scattering and absorption within the silk-screen layer 11. Alternatively, a gradient silk-screen pattern can be designed, where the color or thickness of the silk-screen layer 11 gradually changes from the edge of the lens 2 toward the outside, to better adapt to light incident at different angles and improve overall light absorption efficiency. When designing the silkscreen pattern, optical simulation software should be used to analyze and predict the impact of different patterns on the reflection reduction effect, allowing the optimal design to be selected. Furthermore, the black silkscreen design must be compatible with other designs on the PCB, such as the circuit routing and component layout. Avoid overlapping critical electrical connections, pads, and components in the silkscreen area to prevent impacting the PCB's electrical performance and assembly process. Furthermore, the compatibility of the silkscreen layer 11 with the PCB's surface coating (such as solder mask) must be considered to ensure chemical reactions or poor adhesion between the two. During the design phase, communication and collaboration with PCB design engineers should be strengthened, comprehensively considering both optical and electrical performance requirements to optimize the overall PCB design.

[0052] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the present invention. Anyone skilled in the art may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by one of ordinary skill in the art without departing from the spirit and technical principles disclosed herein are intended to be covered by the claims of the present invention.

Claims

1. A composite light distribution module, characterized in that: Including substrate, lens, lamp beads, wire and shell; A lamp bead and a lens are provided on the upper surface of the substrate, the lamp bead is located in the lens, and the substrate has a silk screen layer, which surrounds the connection between the lens and the substrate; The wires are respectively connected to both ends of the substrate; The housing has a receiving space and is provided with a first opening and a second opening. The substrate is arranged in the receiving space. The raised portion of the lens is arranged at the first opening. The wire is passed through the second opening.

2. The composite light distribution module according to claim 1, characterized in that: The connection between the lens and the substrate is circular, the lamp bead is located at the center of the circle, and the silk-screen layer is provided in an area surrounding the circle.

3. The composite light distribution module according to claim 1 or 2, characterized in that: The silk-screen layer is a black silk-screen layer.

4. The composite light distribution module according to claim 1, characterized in that: The thickness of the silk-screen layer ranges from 10 to 25 μm, and the thickness of the silk-screen layer gradually increases from the edge of the lens to the outside.

5. A method for manufacturing a composite light distribution module, characterized in that: include: The lamp beads and the lens are arranged on the upper surface of the substrate, the lamp beads are arranged in the lens, and the silk screen layer surrounds the connection between the lens and the substrate; wherein the substrate has the silk screen layer; Connect the wires to both ends of the substrate; The substrate is arranged in the accommodation space, the protrusion of the lens is arranged at the first opening, and the wire is passed through the second opening; wherein the housing has an accommodation space and is provided with the first opening and the second opening.

6. The manufacturing method according to claim 5, characterized in that: Also includes: A black silk screen layer is produced; the silk screen layer is a black silk screen layer.

7. The production method according to claim 6, characterized in that: The method of making the black silk screen layer includes: Preheat the acrylate in the ink to 50-60°C to reduce the resin viscosity; Treating carbon black with a silane coupling agent to modify the pigment; Mix the acrylate, solvent, and dispersant and stir at 800-1000 rpm for 10-15 minutes; Add carbon black in portions and stir at 1000-1200 rpm for 20-25 minutes; Use a sand mill to grind the powder to a fineness of 5-15 μm or less; After grinding, add functional additives and mix at 800-900 rpm for 15-20 minutes; Use solvent to dilute the viscosity of the silk screen layer; Use a filter to remove particulate matter.

8. The production method according to claim 7, characterized in that: The ink is one of copper foil substrate matte ink, high hiding UV ink, environmentally friendly water-based ink, and insulating ink.

9. The manufacturing method according to claim 5, characterized in that: Also includes: The lamp bead is arranged at the center of the connection between the lens and the substrate, and the silk-screen layer is arranged in the area surrounding the connection between the lens and the substrate; wherein the connection between the lens and the substrate is circular.

10. The manufacturing method according to claim 5, characterized in that: Also includes: The thickness of the silk-screen layer gradually increases from the edge of the lens to the outside, and the thickness of the silk-screen layer ranges from 10 to 25 μm.

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