Lamp assembly and method of manufacturing a lamp assembly

Abstract

A lamp assembly and a method of making a lamp assembly are disclosed. The lamp assembly (100) includes a housing (10) extending along a first direction (D1), a printed circuit board assembly (20) including a portion located inside the housing (10) and a circuit board extension portion (210) extending outwardly from a first location (P1) of the housing (10), a wiring harness assembly (30) configured to connect with the circuit board extension portion (210), and a first seal (40) configured to seal the housing (10) at the first location (P1) and extend outwardly from the first location (P1) to fit the circuit board extension portion (210) such that the first seal (40) encloses at least a portion of the circuit board extension portion (210).

Description

Technical Field

[0001] This invention relates to a lamp assembly and a method for manufacturing the lamp assembly. Background Technology

[0002] In the manufacturing process of automotive lamp strips, it is usually necessary to seal the strips to make them waterproof, thereby protecting the components inside. However, traditional sealing methods for lamp strips still have the problem of incomplete sealing, which can lead to damage to the light source or other components. Summary of the Invention

[0003] The purpose of this invention is to provide a lamp assembly and a method for manufacturing the lamp assembly.

[0004] On one hand, a lamp assembly is provided, comprising: a housing extending along a first direction; a printed circuit board assembly including a portion located inside the housing and a circuit board extension extending outward from at least a first location of the housing; a wiring harness assembly configured to connect to the circuit board extension; and a first seal configured to seal the housing at the first location and extending outward from the first location to engage the circuit board extension such that the first seal surrounds at least a portion of the circuit board extension.

[0005] In one embodiment, the lamp assembly further includes a support member comprising a support end cap configured to be inserted into the housing at the first position such that the support end cap is located between the housing and the first seal, the support end cap being configured to prevent the first seal from entering the housing; wherein the support end cap includes a first housing positioning structure configured to cooperate with a structure at the first position of the housing to position the support end cap relative to the housing when inserted at the first position.

[0006] In one embodiment, the support further includes a support body connected to the support end cap such that it is located between the circuit board extension and the first seal, the support body being configured to position the circuit board extension and the first seal relative to the housing.

[0007] In one embodiment, a circuit board positioning structure is provided on the surface of the support body facing the printed circuit board assembly, the circuit board positioning structure being configured to restrict the position of the circuit board extension portion at least in the longitudinal and transverse directions of the support body.

[0008] In one embodiment, a first seal positioning structure is provided on the surface of the support body facing the first seal, the first seal positioning structure being configured to be fixedly connected to an external device so as to position the first seal relative to the support; wherein the external device includes a first injection mold for forming the first seal.

[0009] In one embodiment, the wire harness assembly includes: a plurality of wire harnesses; a plug portion disposed at an end of the wire harness assembly and configured to connect to the printed circuit board assembly to connect the plurality of wire harnesses to the printed circuit board assembly; a sealing ring located near the plug portion and configured to surround the plurality of wire harnesses; and a compression ring configured to wrap around the sealing ring to compress the plurality of wire harnesses.

[0010] In one embodiment, the first seal is formed of liquid silicone, and the sealing ring is formed of solid silicone or rubber; and the first seal extends from the first position of the housing to the sealing ring of the wiring harness assembly to bond with the sealing ring.

[0011] In one embodiment, the housing further includes a second position, the second position being an end of the housing in the first direction; and the lamp assembly further includes: a second seal configured to seal the second position of the housing; and an end cap disposed at the second position between the housing and the second seal and configured to be inserted into the housing at the second position, the end cap being configured to prevent the second seal from entering the interior of the housing.

[0012] In one embodiment, a second housing positioning structure is provided on the surface of the end cap facing the housing, the second housing positioning structure being configured to cooperate with a structure at a second position of the housing to position the end cap relative to the housing when inserted at the second position; and a second sealing member positioning structure is provided on the surface of the end cap facing away from the housing, the second sealing member positioning structure being configured to be fixedly connected to an external device to position the second sealing member relative to the end cap; wherein the external device includes a second injection mold for forming the second sealing member.

[0013] In one embodiment, the first position of the housing is located at at least one of a first end, a second end, and a position between the first end and the second end in the first direction of the housing; the angle between the circuit board extension of the printed circuit board assembly and the housing is 180 degrees, 90 degrees, or 0 degrees.

[0014] In one embodiment, the circuit board extension includes a portion of a flexible circuit board extending outward from the housing and a signal input circuit board soldered to the flexible circuit board.

[0015] In one embodiment, the support is connected to the signal input circuit board via a connecting member; the connecting member includes at least one of adhesive, snap-fit ​​structure, riveting structure, and screw.

[0016] On the other hand, a method for manufacturing a lamp assembly is provided, characterized in that the method includes: step S1: manufacturing a housing along a first direction by an extrusion process to house a printed circuit board assembly, and extending a portion of the printed circuit board assembly outward from at least a first position of the housing, such that the printed circuit board assembly includes a portion located inside the housing and a circuit board extension portion located outside the housing, wherein the circuit board extension portion is connected to a wiring harness assembly; and step S2: placing the portion of the housing at the first position, the circuit board extension portion, and a portion of the wiring harness assembly into a first injection mold to manufacture a first seal.

[0017] In one embodiment, step S2 includes: step S21: after inserting the support end cap into the housing at the first position, placing a portion of the housing at the first position with the support end cap, the circuit board extension, and a portion of the wiring harness assembly into a first injection mold to prepare a first seal; step S22: placing the circuit board extension on a support body connected to the support end cap, and connecting the circuit board extension to the support body via a connecting member; and preparing the first seal by fixing the support body to the first injection mold.

[0018] In one embodiment, the method further includes: step S3: inserting the end cap into the housing at a second position; and preparing a second seal by fixing the end cap to a second injection mold, thereby placing the portion of the housing at the second position and the end cap into the second injection mold. Attached Figure Description

[0019] Figure 1 A perspective view of a lamp assembly according to an embodiment of the present invention is shown.

[0020] Figure 2 It shows according to Figure 1 Cross-sectional view of the lamp assembly.

[0021] Figure 3 It shows according to Figure 1 An exploded view of the lamp assembly.

[0022] Figure 4 A perspective view of a support member according to an embodiment of the present invention is shown.

[0023] Figure 5 A perspective view of a wire harness assembly according to an embodiment of the present invention is shown.

[0024] Figure 6 An exploded view of a wire harness assembly according to an embodiment of the present invention is shown.

[0025] Figure 7 A perspective view of an end cap according to an embodiment of the present invention is shown.

[0026] Figure 8 It shows Figure 1 A partial structural diagram of the lamp assembly shown from another angle.

[0027] Figure 9 A diagram of a lamp assembly according to another embodiment of the present invention is shown.

[0028] Figure 10 It shows according to Figure 9 An exploded view of the lamp assembly.

[0029] Figure 11 A diagram of a lamp assembly according to another embodiment of the present invention is shown.

[0030] Figure 12 A diagram of a lamp assembly according to another embodiment of the present invention is shown.

[0031] Figure 13 It shows according to Figure 12 A partial structural diagram of the lamp assembly.

[0032] Figure 14 A diagram of a lamp assembly according to another embodiment of the present invention is shown.

[0033] Figure 15 It shows according to Figure 14 A partial structural diagram of the lamp assembly.

[0034] Figure 16 The preparation is shown Figure 1 Exemplary steps of the method for assembling the lamp shown. Detailed Implementation

[0035] The technical solution of the present invention will be further described in detail below through embodiments and in conjunction with the accompanying drawings. In this specification, the same or similar reference numerals denote the same or similar components. The following description of the embodiments of the present invention with reference to the accompanying drawings is intended to explain the overall inventive concept of the present invention and should not be construed as a limitation thereof.

[0036] Furthermore, in the following detailed description, numerous specific details are set forth for ease of explanation to provide a thorough understanding of the embodiments disclosed herein. However, it will be apparent that one or more embodiments may be practiced without these specific details.

[0037] Figure 1 A perspective view of a lamp assembly 100 according to an embodiment of the present invention is shown. Figure 2 The invention is shown Figure 1 The diagram shows a cross-sectional view of the lamp assembly. Figure 3 The invention is shown Figure 1 An exploded view of the lamp assembly 100 shown.

[0038] like Figure 1-3 As shown, the lamp assembly 100 includes a housing 10 and a printed circuit board assembly 20. The lamp assembly 100 may be in the form of a flexible strip. The housing 10 extends along a first direction D1. The printed circuit board assembly 20 may include a portion located inside the housing 10 and a circuit board extension portion 210 extending outward from at least a first position P1 of the housing 10. As an example, the portion of the printed circuit board assembly 20 inside the housing 10 may extend along the entire length of the housing 10 and may include a flexible circuit board and a plurality of light sources (i.e., flexible lamp panels) disposed thereon, the plurality of light sources being spaced apart on the flexible circuit board along the first direction D1. The flexible lamp panels may be disposed inside the housing 10 while being extruded from the housing 10. The housing 10 may surround the portion of the printed circuit board assembly 20 inside the housing 10, and the housing 10 may specifically include a reflective layer and a light-emitting layer interconnected, with a gap between the flexible lamp panel and the reflective layer and the light-emitting layer. The light emitted by multiple light sources is reflected by the reflective layer inside the housing 10 and then emitted to the outside from the emission surface 110 of the light-emitting layer of the housing 10, thereby forming a light strip for illuminating the outside.

[0039] The printed circuit board assembly 20 may extend beyond the housing 10 to form a circuit board extension 210 of the printed circuit board assembly 20 located outside the housing 10. For example... Figure 1-3 As shown, the lamp assembly 100 also includes a wiring harness assembly 30. The wiring harness assembly 30 is configured to connect to the circuit board extension 210, such that the wiring harness assembly 30 can transmit signals and power to multiple light sources on the printed circuit board assembly 20 via the circuit board extension 210, thereby enabling the multiple light sources to be lit in a desired manner.

[0040] The lamp assembly 100 also includes a first seal 40. This first seal 40 is configured to seal the housing 10 at a first position P1. Herein, "first position P1" can be understood as the location where the housing 10 is configured to extend the printed circuit board assembly 20. That is, the printed circuit board assembly 20 is configured to extend outward from the first position P1 of the housing 10 to connect with the wiring harness assembly 30. In this case, the housing 10 will have an opening at the first position P1 through which the printed circuit board assembly 20 extends outward. Therefore, during the subsequent fabrication of the lamp assembly, this opening of the housing 10 needs to be sealed to prevent external liquids or other contaminants from entering the housing 10 through the opening and contaminating or damaging the multiple light sources.

[0041] exist Figure 1-3 In the embodiment of the lamp assembly 100 shown, the first position P1 is at one end of the housing 10 in the first direction D1, that is, at Figure 1 The housing 10 is located at its left end. Typically, the housing 10 is fabricated using an extrusion process, for example, by integrally extruding silicone to form a flexible housing 10. That is, the housing 10 is continuously extruded onto a continuous flexible lamp board to assemble into a lamp strip, and then the continuously extruded lamp strip is cut into segments according to the required length, thereby forming multiple individual lamp strips. Since the cutting process creates an opening at the end of the housing 10, the opening at the end is usually used to directly lead out the circuit board extension portion 210, such as... Figure 1-3 As shown in the diagram. However, embodiments of the invention are not limited thereto. The first position P1 may be at the other end of the housing 10 in the first direction D1 (e.g., the right end of the housing 10). Alternatively, in some longer light strips, in order to reduce the adverse effects of voltage drop on the lighting effect of the light source, the first position P1 may be at both ends of the housing 10 in the first direction D1, i.e., with dual-end power supply, or the first position P1 may be at the middle position between the two ends, or it may be at other positions as needed.

[0042] According to an embodiment of the present invention, a first seal 40 is used to seal the opening of the housing 10 at a first position P1. As an example, the first seal 40 may be partially connected to the housing 10 at the first position P1, such that the first seal 40 completely covers the opening of the housing 10 at the first position P1, thereby achieving a sealing effect on the housing 10. Additionally or optionally, the first seal 40 may be formed to at least partially surround the housing 10 at the first position P1, such that there is an overlap between the first seal 40 and the housing 10 in the first direction D1, thereby further enhancing the stable connection between the first seal 40 and the housing 10 and further ensuring the sealing performance of the housing 10. Optionally, there may be no overlap between the first seal 40 and the housing 10 on the emission surface 110 of the housing 10, i.e., the first seal 40 does not cover the emission surface 110, thereby maximizing the surface area of ​​the emission surface 110 to maximize the lighting range and efficiency of the lamp assembly 100.

[0043] Furthermore, the first seal 40 is also configured to extend outward from the first position P1 to engage with the circuit board extension 210, such that the first seal 40 surrounds at least a portion of the circuit board extension 210. As described above, the circuit board extension 210 needs to extend to the outside of the housing 10 to connect with the wiring harness assembly 30, thereby making the circuit board extension 210 susceptible to damage from external liquids or other contaminants. Therefore, according to an embodiment of the invention, the first seal 40 includes, in addition to the portion corresponding to the opening at the first position P1 of the housing 10, a portion corresponding to the circuit board extension 210, such that the first seal 40 protects the circuit board extension 210 by surrounding at least a portion of the circuit board extension 210.

[0044] As an example, after connecting the circuit board extension 210 to the wiring harness assembly 30, the first seal 40 can be manufactured by injection molding by placing the portion at the first position P1 of the housing 10 and the circuit board extension 210 together into an injection mold. Thus, the first seal 40 can be formed to fit the circuit board extension 210 (e.g., to fit the size, shape, etc. of the circuit board extension 210) so that the first seal 40 surrounds at least a portion of the circuit board extension 210. For example, in... Figure 1-3In the illustrated embodiment, the first seal 40 is formed to surround the two side surfaces of the circuit board extension 210 and the surface facing away from the housing 10, thereby preventing liquids (e.g., water) outside the lamp assembly 100 from damaging the circuit board extension 210. In other embodiments, the first seal 40 may be formed to completely surround the circuit board extension 210, such that the circuit board extension 210 is entirely located inside the first seal 40. However, embodiments of the present invention are not limited to this, and the extent to which the first seal 40 surrounds the circuit board extension 210 can be specifically configured according to actual needs.

[0045] In this way, by providing a first seal 40 at the first position P1 where the printed circuit board assembly 20 extends from the housing 10, not only can the opening of the housing 10 for leading out the printed circuit board assembly 20 be sealed to protect the flexible printed circuit board and multiple light sources (i.e., flexible lamp boards) inside the housing 10 from damage, but the circuit board extension 210 extending from the housing 10 to the outside of the housing can also be sealed to isolate the circuit board extension 210 from external liquids or other contaminants.

[0046] In one embodiment, such as Figure 3 As shown, the lamp assembly 100 also includes a support member 50. This support member 50 includes a support end cap 510, which is configured to insert into the housing 10 at a first position P1 such that the support end cap 510 is located between the housing 10 and the first seal 40, and the support end cap 510 is configured to prevent the first seal 40 from entering the housing 10. As an example, an opening may be present at the first position P1 where the support end cap 510 is inserted into the housing 10 (in... Figure 1-3 In the embodiment, after the left end of the housing 10 is provided, a first seal 40 is formed by injection molding with a support end cap 510, such that the first seal 40 is formed outside the support end cap 510. In this way, the first seal 40 can be prevented from directly sealing the opening of the housing 10 by providing the support end cap 510. Typically, the first seal 40 is formed of liquid silicone. That is, during the injection molding process of the first seal 40, flowing liquid silicone is injected into the injection mold, and after filling the injection mold, the liquid silicone is solidified to form the first seal 40 of the desired shape. Therefore, if the first seal 40 directly seals the opening of the housing 10, that is, if the support end cap 510 is not provided between the first seal 40 and the housing 10, liquid silicone may flow through the opening of the housing 10 and enter the interior of the housing 10 during the injection molding process, which may damage the flexible lamp plate inside the housing 10. Therefore, by pre-inserting and sealing the opening of the housing 10 with the support end cap 510, and then performing the injection molding process in a sealed state, liquid silicone can be prevented from flowing into the interior of the housing 10.

[0047] Figure 4 A perspective view of a support member 50 according to an embodiment of the present invention is shown.

[0048] In one embodiment, such as Figure 3-4 As shown, the support end cap 510 may include a first housing positioning structure 5001. This first housing positioning structure 5001 is configured to mate with a structure at a first position P1 of the housing 10, so as to position the support end cap 510 relative to the housing 10 when inserted at the first position P1. As an example, the first housing positioning structure 5001 may be formed to include a complementary structure corresponding to the structure at the opening of the housing 10. That is, the first housing positioning structure 5001 may correspond to the structure at the opening of the housing 10, such that the first housing positioning structure 5001 can be stably inserted into the corresponding complementary structure in the housing 10, thereby stably connecting to the housing 10. For example, as... Figure 4 As shown, the first housing positioning structure 5001 may include multiple substructures corresponding to complementary portions at the opening of the housing 10, such that each substructure can be inserted into its respective complementary structure. In this way, by providing the first housing positioning structure 5001, the support end cap 510 can be positioned in the correct sealing position relative to the housing 10 to completely and properly seal the opening of the housing 10, thereby ensuring that liquid silicone does not flow into the interior of the housing 10. Furthermore, the complementary configuration of the support end cap 510 and the structure at the opening of the housing 10 enables a robust connection between the two to improve sealing stability.

[0049] In one embodiment, such as Figure 3-4 As shown, the support member 50 also includes a support body 520. This support body 520 is connected to the support end cap 510, positioned between the circuit board extension 210 and the first seal 40, to better protect the flexible circuit board and reduce or avoid pulling. As an example, the support body 520 and the support end cap 510 can be integrally formed to obtain the support member 50. Alternatively, the support body 520 and the support end cap 510 can be formed separately, and the support member 50 is obtained by connecting the support body 520 and the support end cap 510 together (e.g., by connecting members or by adhesive, etc.) during the fabrication of the lamp assembly 100. Of course, in some embodiments, the support body 520 may not be connected to the support end cap 510. As described above, the first seal 40 is injection molded after the support end cap 510 is inserted. Therefore, when inserting the support end cap 510 to position the support member 50, the support body 520 can be positioned first, and then the first seal 40 can be formed, such that the first seal 40 is formed outside the support body 520.

[0050] Furthermore, the support body 520 can be configured to position the circuit board extension 210 and the first seal 40 relative to the housing 10. For example... Figure 3 As shown, the support body 520 is configured to correspond to the circuit board extension 210, thereby supporting the circuit board extension 210. In this way, since the support member 50 is positioned relative to the housing 10 via the support end cap 510, the support body 520 within the support member 50 is also positioned accordingly. Therefore, the circuit board extension 210 can be positioned by the support body 520 supporting it. Furthermore, since the first seal 40 is formed after the support body 520 is provided, the first seal 40 is formed in conjunction with the support body 520, so that the support body 520 also positions the first seal 40. Thus, the first seal 40 can be appropriately formed relative to the support body 520 and the circuit board extension 210 supported by the support body 520, thereby ensuring optimal matching in shape, position, etc., between these components to improve the sealing effect.

[0051] In one embodiment, such as Figure 3-4 As shown, a circuit board positioning structure 5002 is provided on the surface of the support body 520 facing the printed circuit board assembly 20. This circuit board positioning structure 5002 is configured to restrict the position of the circuit board extension portion 210 at least in the longitudinal and transverse directions of the support body 520. As an example, such as... Figure 4 As shown, the circuit board positioning structure 5002 may include a first set of positioning members 5012 and a second set of positioning members 5022. The two sets of positioning members extend outward from the surface of the support body 520 facing the printed circuit board assembly 20 in a direction perpendicular to the surface, to cooperate with at least a portion of the circuit board extension 210, such that a corresponding portion of the circuit board extension 210 can be placed in the positioning space formed by the two sets of positioning members 5012 and 5022, so that the two sets of positioning members 5012 and 5022 can positionally restrict or fix the circuit board extension 210. The first set of positioning members 5012 and the second set of positioning members 5022 may be spaced apart from each other on the support body 520, so that the circuit board extension 210 can be restricted or fixed in the longitudinal direction of the support body 520. Furthermore, each of the first set of positioning members 5012 and the second set of positioning members 5022 includes two positioning members disposed opposite each other on the side edge of the support body 520, so that the circuit board extension 210 is restricted or fixed in the transverse direction of the support body 520, respectively. The first set of positioning components 5012, in conjunction with the support body 520, can restrict the position of the circuit board extension 210 in the height direction of the support body 520. In this way, the circuit board extension 210 is constrained in all six degrees of freedom.

[0052] However, the embodiments of the present invention are not limited to this. The circuit board positioning structure 5002 can be set with different structures, as long as the set structure can fix or restrict the position of the circuit board extension portion 210 in the longitudinal and transverse directions of the support body 520.

[0053] In one embodiment, such as Figure 3-4 As shown, a first seal positioning structure 5003 is provided on the surface of the support body 520 facing the first seal 40. This first seal positioning structure 5003 is configured to be fixedly connected to an external device, allowing the first seal 40 to be positioned relative to the support body 50. As an example, such as... Figure 4 As shown, the first sealing element positioning structure 5003 can extend outward from the surface of the support body 520 facing the first sealing element 40 in a direction perpendicular to said surface. Furthermore, the first sealing element positioning structure 5003 can be composed of two structurally identical sub-components, and each sub-component can have its own mounting hole, allowing the first sealing element positioning structure 5003 to be fixedly connected to an external device through these mounting holes. For example, the support member 50 can be fixed to the external device by fixing the mounting holes to corresponding structures (e.g., latching mechanisms, pins, etc.) on the external device.

[0054] As described above, after the support member 50 is installed onto the housing 10 and the printed circuit board assembly 20, an injection mold is used to prepare the first seal 40. According to an embodiment of the invention, the external device may include a first injection mold for forming the first seal 40. As an example, when preparing the first seal 40, the support member 50 can be fixed to the first injection mold via a fixed connection between the first seal positioning structure 5003 on the support member 50 and a mating structure in the first injection mold. Furthermore, the housing 10 and the printed circuit board assembly 20 are already positioned relative to the support member 50 due to the positioning action of the first housing positioning structure 5001 and the circuit board positioning structure 5002 on the support member 50. Therefore, the housing 10 and the printed circuit board assembly 20 can be held in a suitable position relative to the first injection mold to ensure optimal injection molding results, such that the resulting first seal 40 can provide optimal sealing to the opening in the housing 10 and the circuit board extension 210.

[0055] In this way, by providing a support member 50 and providing a first housing positioning structure 5001, a circuit board positioning structure 5002, and a first seal positioning structure 5003 on the support member 50, during the fabrication of the first seal 40, while preventing the liquid silicone used to form the first seal 40 from entering the interior of the housing 10, it is also possible to maintain accurate positioning of the housing 10, the circuit board extension 210, and the first injection mold relative to each other, thereby ensuring the sealing performance of the formed first seal 40. It is worth noting that the support member 50 is typically rigid, which ensures its effective fulfillment of its support and positioning functions. Preferably, the first seal positioning structure 5003 can be used as a vehicle body fixing structure that can be connected to vehicle body components, so that after the lamp assembly 100 is fabricated, this vehicle body fixing structure can be used to install and fix the lamp assembly 100 inside the vehicle.

[0056] Figure 5 A perspective view of a wire harness assembly 30 according to an embodiment of the present invention is shown. Figure 6 An exploded view of a wire harness assembly 30 according to an embodiment of the present invention is shown.

[0057] In one embodiment, the wiring harness assembly 30 may include a plurality of wire harnesses 310 and a plug portion 320. The plug portion 320 is disposed at an end of the wiring harness assembly 30 and configured to be soldered to a printed circuit board assembly 20 to connect the plurality of wire harnesses 310 to the printed circuit board assembly 20. The other end of the wiring harness assembly 30 is connected to a connector for connecting external power supply circuitry, drive circuitry, and / or control circuitry. As an example, such as... Figure 3 , 5 As shown in Figure 6, the plug portion 320 may include a plurality of connectors 3201. The printed circuit board assembly 20 may include a plurality of sockets 3202. The number of connectors 3201 corresponds one-to-one with the number of sockets 3202, such that each connector 3201 can be inserted into its respective socket 3202. Furthermore, the plurality of connectors 3201 may correspond one-to-one with a plurality of wire harnesses 310, such that each wire harness 310 can be connected to its respective connector 3201. Thus, by connecting the plurality of connectors 3201 to the plurality of sockets 3202, the connection between the plurality of wire harnesses 310 and the printed circuit board assembly 20 can be realized, thereby enabling the wire harness assembly 30 to transmit signals and power to multiple light sources inside the housing 10.

[0058] like Figure 5 and 6As shown, the wire harness assembly 30 also includes a sealing ring 330 and a compression ring 340. The sealing ring 330 may be located near the plug portion 320 and configured to surround the plurality of wire harnesses 310. As an example, the sealing ring 330 may be formed to integrally surround a portion of the plurality of wire harnesses 310 in the longitudinal direction from the outside of the plurality of wire harnesses 310, such that the sealing ring 330 can seal the plurality of wire harnesses 310 relative to the outside. Further, the sealing ring 330 may be formed as a solid structure rather than a hollow structure, and has a plurality of through holes formed in the longitudinal direction inside, such that the plurality of wire harnesses 310 can each pass through a corresponding through hole, thereby passing through the sealing ring 330 in the longitudinal direction. Thus, the sealing ring 330 can also seal between the plurality of wire harnesses 310 and each other.

[0059] The compression ring 340 can be configured to wrap around the sealing ring 330 to compress the plurality of wire harnesses 310. As an example, the compression ring 340 can be provided with an inward contraction pressure to compress the sealing ring 330 inward when wrapped around it, thereby promoting tight contact between the sealing ring 330 and the plurality of wire harnesses 310. Figure 5 As shown, the compression ring 340 does not need to completely cover the sealing ring 330; instead, it can overlap only a portion of the sealing ring 330, leaving the other part of the sealing ring 330 exposed. In this way, by using the sealing ring 330 and the compression ring 340 in combination, a tight contact can be formed between the multiple wire harnesses 310, the sealing ring 330, and the compression ring 340, avoiding any gaps. The sealing ring 330 cooperates with the injection mold for sealing. This will prevent the liquid silicone used to form the first seal 40 from flowing out of the wire harness assembly 30 when the first seal 40 is manufactured using the injection molding process. That is, through the tight contact between the multiple wire harnesses 310, the sealing ring 330, and the compression ring 340, a tight barrier can be formed to prevent the possible flow of liquid silicone from the wire harness assembly 30. Furthermore, since each wire harness passes through the sealing ring individually, there are no gaps between the wire harnesses; after injection molding, moisture can be prevented from entering the circuit board area between the wire harnesses, avoiding any impact or contamination to the circuit board area.

[0060] In one embodiment, the first seal 40 may be formed of liquid silicone, and the sealing ring 330 may be formed of solid silicone or rubber. It is worth noting that in other embodiments, the materials of the first seal 40 and the sealing ring 330 may be other materials. The first seal 40 is formed as an extension from a first position P1 of the housing 10 to the sealing ring 330 of the wiring harness assembly for adhesive engagement. Figure 1-3In the illustrated embodiment, the first injection mold for forming the first seal 40 can be formed to have the same length as the distance from the left end of the housing 10 (i.e., the first position P1) to the sealing ring 330 in the wiring harness assembly 30 in connection with the printed circuit board assembly 20. That is, when the housing 10 and the printed circuit board assembly 20 are placed into the first injection mold to prepare for the fabrication of the first seal 40, one end of the first injection mold corresponds to the left end of the housing 10, and the other end corresponds to the sealing ring 330. Thus, the first seal 40 can be formed to contact the sealing ring 330 at this other end.

[0061] In this way, due to the solid silicone or rubber material properties of the sealing ring 330, the sealing ring 330 can directly bond with the first seal 40 of the liquid silicone, thereby improving the connection stability of the first seal 40 at the sealing ring 330. Therefore, after the lamp assembly 100 is formed, the first seal 40 will not easily fall off due to this adhesive bonding and will maintain optimal sealing performance. Furthermore, as described above, the gaps between the wire harnesses 310 are pressed together by the sealing ring 330, and the sealing ring 330 and the injection molding liquid silicone can be tightly bonded, forming a tight barrier at the sealing ring 330. This prevents the liquid silicone from flowing out of the first injection mold and thus failing to form the first seal 40 with sufficient material, and also ensures that moisture does not enter the circuit board area from the location of the sealing ring 330.

[0062] In one embodiment, the lamp assembly 100 further includes a second seal 60 and an end cap 70. Figure 7 A perspective view of the end cap 70 according to an embodiment of the present invention is shown. Figure 8 It shows Figure 1 The diagram shows a partial structural view of the lamp assembly 100 from another angle, in which the second seal 60 is not yet sealed to the outside of the end cap 70.

[0063] The second seal 60 can be configured to seal the second position P2 of the housing 10. According to an embodiment of the invention, the second position P2 can be an end of the housing 10 in the first direction D1. As described above, typically after extrusion forming of the housing 10, cutting is required to obtain the desired lamp assembly length. Therefore, openings formed due to cutting will exist at both ends of the housing 10. Figure 1-3In the illustrated embodiment, one of the two end openings is used to lead out the printed circuit board assembly 20, and is therefore sealed by the first seal 40. The other end opening may be empty, but since such an opening may allow external liquids (e.g., water) or other contaminants to enter the housing 10, it also needs to be sealed. Therefore, for such an empty end opening of the housing 10, a second seal 60 can be used. Since this empty end opening is not used to lead out the printed circuit board assembly 20, the structure of the second seal 60 may not include the portion corresponding to the printed circuit board assembly 20, and therefore the structure of the second seal 60 can be simpler than the structure of the first seal 40. Additionally, in other embodiments, when both end openings of the housing 10 are empty (e.g., when the first position P1 is in the middle position of the housing 10), the second seal 60 can be used at both end openings of the housing 10, for example as... Figure 9-10 As shown.

[0064] As an example, such as Figure 1-3 As shown, the second seal 60 can be formed as an extension of the housing 10 in the first direction D1, such that the second seal 60 is flush with the circumferential edge of the end opening of the housing 10, thereby sealing the end opening of the housing 10.

[0065] like Figure 3 , 7 As shown in Figure -8, the end cap 70 is disposed at a second position P2 between the housing 10 and the second seal 60, and is configured to be inserted into the housing 10 at the second position P2. As an example, before the second seal 60 is manufactured by injection molding, the end cap 70 can be inserted into the end opening of the housing 10. Then, liquid silicone is injection molded onto the end of the housing 10 with the end cap 70 to form the second seal 60, such that the second seal 60 is formed outside the end cap 70. For example, as... Figure 8As shown, the end cap 70 can be designed to match the size of the end opening of the housing 10, ensuring a stable connection and preventing it from easily detaching after insertion. In this way, by placing the end cap 70 between the housing 10 and the second seal 60, direct sealing of the housing 10 by the second seal 60 can be prevented. That is, similar to the support end cap 510 of the support member 50, if the second seal 60 is directly injection molded at the end opening of the housing 10, the liquid silicone used to form the second seal 60 may flow into the housing 10 through this end opening during injection molding, potentially contaminating or damaging the light source or other components inside the housing 10. Therefore, by pre-inserting the end cap 70 and then injection molding the second seal 60, the flow of liquid silicone into the housing 10 during injection molding can be avoided. Furthermore, by providing both the second seal 60 and the end cap 70 at the end opening of the housing 10, the sealing performance can be further enhanced.

[0066] According to embodiments of the present invention, the support end cap 510 and the end cap 70 can be made of materials having adhesive properties to liquid silicone, so that the formed first seal 40 and second seal 60 can be bonded to the support end cap 510 and the end cap 70 respectively, thereby ensuring sealing stability. For example, the material of the support end cap 510 and the end cap 70 can be polycarbonate (PC). Additionally or alternatively, an adhesive (e.g., glue) can be applied to the support end cap 510 and the end cap 70 respectively for adhesive bonding to the first seal 40 and the second seal 60.

[0067] In one embodiment, such as Figure 7 As shown, a second housing positioning structure 7001 is provided on the surface of the end cap 70 facing the housing 10. This second housing positioning structure 7001 is configured to cooperate with a structure at a second position P2 of the housing 10, so that the end cap 70 can be positioned relative to the housing 10 when inserted at the second position P2. As an example, the second housing positioning structure 7001 can be formed to include a complementary structure corresponding to the structure at the end opening of the housing 10. That is, the second housing positioning structure 7001 can correspond to the structure at the end opening of the housing 10, such that the second housing positioning structure 7001 can be stably inserted into the corresponding complementary structure in the housing 10, thereby stably connecting to the housing 10. For example, as... Figure 7As shown, the second housing positioning structure 7001 may include multiple substructures corresponding to corresponding complementary portions at the end openings of the housing 10, such that each substructure can be inserted into its respective complementary structure. In this way, by providing the second housing positioning structure 7001, the end cap 70 can be positioned in the correct sealing position relative to the housing 10 to completely and properly seal the end openings of the housing 10, thereby ensuring that liquid silicone does not flow into the interior of the housing 10. Furthermore, the complementary configuration of the end cap 70 and the structures at the end openings of the housing 10 enables a robust connection between them to improve sealing stability. The second housing positioning structure 7001 and the first housing positioning structure 5001 can be the same structure.

[0068] In one embodiment, such as Figure 7 As shown, a second sealing element positioning structure 7002 is provided on the surface of the end cap 70 facing away from the housing 10. This second sealing element positioning structure 7002 is configured to be fixedly connected to an external device, allowing the second sealing element 60 to be positioned relative to the end cap 70. As an example, similar to the first sealing element positioning structure 5003, the second sealing element positioning structure 7002 can fix the end cap 70 to the external device by being fixedly connected to a corresponding structure on the external device.

[0069] According to an embodiment of the present invention, the external device may include a second injection mold for forming the second seal 60. As described above, the injection molding process begins only after the end cap 70 is installed. Therefore, when the end of the housing 10 with the end cap 70 is placed into the second injection mold, the end cap 70 is fixed to the second injection mold by the second seal positioning structure 7002 to position the end cap 70 relative to the second injection mold. Since the end cap 70 is also stably inserted and connected to the end of the housing 10, the position of the housing 10 is also positioned relative to the second injection mold when positioning the end cap 70 relative to the second injection mold. In this way, it can be ensured that the end of the housing 10 is always in the proper position in the second injection mold during injection molding, thereby properly forming the second seal 60 relative to the end of the housing 10. Thus, the second seal 60 can perfectly correspond to the end edge of the housing 10 to provide aesthetics of the lamp assembly 100 and save material costs, while also ensuring a satisfactory sealing effect on the end opening of the housing 10.

[0070] According to an embodiment of the present invention, the first position P1 of the housing 10 may be located at the first end (e.g., the left end) in the first direction D1 of the housing 10, as described above. Figure 1-3As illustrated in the given embodiment. In another embodiment, the first position P1 may be located at a second end in a first direction D1 of the housing 10, wherein the second end may be opposite to the first end. For example, the second end may be at the right end.

[0071] In this configuration, the circuit board extension 210 may include a portion of the flexible circuit board 2001 extending outward from the housing 10 and a signal input circuit board 2002 soldered to the flexible circuit board 2001. The signal input circuit board 2002 is typically a rigid board. As an example, after the LED strip is cut to the desired length, a portion of the flexible circuit board 2001 of the housing 10 can be extended outward and then soldered to the signal input circuit board 2002. The signal input circuit board 2002 may be pre-connected to multiple wire harnesses 310. In this way, signals and power from the wire harness assembly 30 can be transmitted to the flexible circuit board 2001 via the signal input circuit board 2002 to control the lighting effect of multiple light sources on the flexible circuit board 2001.

[0072] In other embodiments, the first position P1 may be located at a position between the first end and the second end of the housing 10. Figure 9 A diagram of a lamp assembly 100 according to another embodiment of the present invention is shown. Figure 10 It shows according to Figure 9 An exploded view of the lamp assembly 100. (See attached diagram.) Figure 9-10 As shown, the first position P1 is not located at an end of the housing 10, but rather at the middle position of the housing 10. In this case, both ends of the housing 10 are sealed by the second seal 60, and the opening at the middle position is sealed by the first seal 40. Figure 9-10 In the illustrated embodiment, the first seal 40 can be formed to completely surround both circuit board extensions 210, and the support member 50 may be omitted if waterproofing requirements are not high. However, embodiments of the present invention are not limited to this; the first seal 40 may only surround a portion of the circuit board extension 210, and the support member 50 may be provided to enhance protective performance. This can be modified according to specific needs.

[0073] In this configuration, the circuit board extension 210 may include a portion of the flexible circuit board 2001 extending outward from the housing 10 and a signal input circuit board 2002 soldered to the flexible circuit board 2001. Typically, the signal input circuit board 2002 is a rigid board. The flexible circuit board 2001 extending outward from the housing 10 is bent out from a flexible circuit board inside the housing 10. Figure 9-10As shown, when the first position P1 is located between the first and second ends of the housing 10 (e.g., the middle position), the flexible circuit board 2001 can be configured to bend out from inside the housing 10 at the first position P1 and extend outward from the housing 10 at the first position P1 to be soldered to the signal input circuit board 2002, thereby connecting the signal input circuit board 2002 to the flexible circuit board 2001. Thus, signals and power from the wiring harness assembly 30 can be transmitted to the flexible circuit board 2001 via the signal input circuit board 2002 to control the lighting effect of multiple light sources on the flexible circuit board.

[0074] In manufacturing, a flexible light panel can be provided first, comprising a flexible circuit board extending along a first direction D1 and a plurality of light sources spaced apart along the first direction D1 on the front side of the flexible circuit board. Then, a housing 10 is integrally extruded onto the flexible light panel. A portion at a first position P1 on the housing 10 is removed to expose the back side of the flexible circuit board. The flexible circuit board is then cut. Next, the flexible circuit board is bent at the first position P1. The bent flexible circuit board is then electrically soldered to a signal input circuit board 2002, which has been pre-connected to a wiring harness assembly 30. Finally, a first seal 40 is injection molded.

[0075] Figure 11 A diagram showing a lamp assembly 100 according to another embodiment of the present invention is provided. Figure 11 As shown, the first position P1 can be located at the first end, the second end, and the middle position of the housing 10. This is because the lamp assembly 100 may be a large lamp assembly, which may require more power and signal input, thus requiring more wiring harness assemblies 30. In this case, the second seal 60 can be omitted, and the first seal 40 can be provided at all openings.

[0076] exist Figure 1-3 In the illustrated embodiment, the circuit board extension 210 of the printed circuit board assembly 20 is configured to bend such that the circuit board extension 210 also extends parallel to the housing 10 in the first direction D1. Therefore, the angle between the circuit board extension 210 and the housing 10 is 0 degrees. In other embodiments, the circuit board extension 210 may be formed to have a different angle with the housing 10. Figure 12 A diagram of a lamp assembly 100 according to another embodiment of the present invention is shown. Figure 13 It shows according to Figure 12 The diagram shows a partial structural representation of the lamp assembly, with the first seal 40 removed. (See diagram for reference.) Figure 12-13 As shown, the angle between the circuit board extension 210 and the housing 10 is 90 degrees. Figure 14 A diagram of a lamp assembly 100 according to another embodiment of the present invention is shown. Figure 15It shows according to Figure 14 The diagram shows a partial structure of the lamp assembly 100, with the first seal 40 removed. (See diagram for reference.) Figure 14-15 As shown, the angle between the circuit board extension 210 and the housing 10 is 180 degrees. However, it should be noted that the embodiments of the present invention are not limited to this, and different angles can be formed between the circuit board extension 210 and the housing 10 according to actual needs.

[0077] In one embodiment, the support body 520 of the support member 50 can be connected to the signal input circuit board 2002 via a connecting member, thereby facilitating the circuit board positioning structure 5002 on the support body 520 to limit the position of the circuit board extension 210. For example, the connecting member may include at least one of adhesive, snap-fit ​​structure, riveting structure, and screw.

[0078] The present invention also provides a method for manufacturing a lamp assembly 100. In the following, the method of manufacturing... Figure 1-3 The method of the lamp assembly 100 in the illustrated embodiment is described as an example. It should be understood that this example method is also applicable to other embodiments of the lamp assembly 100.

[0079] Figure 16 The preparation is shown Figure 1 Exemplary steps of the method for the lamp assembly 100 shown.

[0080] like Figure 16 As shown, in step S1, the housing 10 is prepared along the first direction D1 by an extrusion process so that the printed circuit board assembly 20 is installed in the housing 10 and a portion of the printed circuit board assembly 20 extends outward from at least the first position P1 of the housing 10, such that the printed circuit board assembly 20 includes a portion located inside the housing 10 and a circuit board extension portion 210 located outside the housing 10, wherein the circuit board extension portion 210 is connected to the wire harness assembly 30.

[0081] In some embodiments, step S1 may include soldering a flexible circuit board 2001 extending outside the housing to a signal input circuit board 2002, and connecting a wiring harness assembly 30 to the signal input circuit board 2002.

[0082] In step S2, a portion of the housing 10 at the first position P1, the circuit board extension 210, and a portion of the wiring harness assembly 30 are placed into the first injection mold to prepare the first seal 40.

[0083] In one embodiment, step S2 may include steps S21-S22.

[0084] In step S21, after inserting the support end cap 510 into the housing 10 at the first position P1, the portion of the housing 10 at the first position P1 with the support end cap 510, the circuit board extension portion 210, and a portion of the wiring harness assembly 30 are placed into the first injection mold to prepare the first seal 40.

[0085] In step S22, the circuit board extension 210 is placed on the support body 520 connected to the support end cap 510, and the circuit board extension 210 is connected to the support body 520 via a connecting member. The first seal 40 is prepared by fixing the support body 520 to the first injection mold.

[0086] In step S3, the end cap 70 is inserted into the housing 10 at the second position P2. The second seal 60 is prepared by fixing the end cap 70 to the second injection mold, thereby placing the portion of the housing 10 at the second position P2 and the end cap 70 into the second injection mold.

[0087] In some embodiments, the first position P1 is located at at least one of the first end, the second end, and the position between the first end and the second end on the first direction D1 of the housing 10. The second position P2 is at least one of the first end and the second end of the housing 10 on the first direction D1.

[0088] The present invention also provides a motor vehicle that may include a lamp assembly 100 according to an embodiment of the present invention.

[0089] Although the invention has been described in conjunction with the accompanying drawings, the embodiments disclosed in the drawings are intended to illustrate preferred embodiments of the invention and should not be construed as limiting the invention.

[0090] While some embodiments of the general concept of the present invention have been shown and described, those skilled in the art will understand that changes may be made to these embodiments without departing from the principles and spirit of the general inventive concept, the scope of which is defined by the claims and their equivalents.

Claims

1. A lamp assembly (100), characterized in that, include: A housing (10) extending along a first direction (D1); Printed circuit board assembly (20), the printed circuit board assembly including a portion located inside the housing (10) and a circuit board extension portion (210) extending outward from at least a first position (P1) of the housing (10); A wiring harness assembly (30) configured to connect to the circuit board extension (210); and A first seal (40) is configured to seal the housing (10) at the first position (P1) and extend outward from the first position (P1) to engage the circuit board extension (210) such that the first seal (40) surrounds at least a portion of the circuit board extension (210).

2. The lamp assembly (100) according to claim 1, the lamp assembly further comprising a support member (50), the support member (50) comprising a support end cap (510), the support end cap (510) being configured to be inserted into the housing (10) at the first position (P1) such that the support end cap (510) is located between the housing (10) and the first seal (40), the support end cap (510) being configured to prevent the first seal (40) from entering the interior of the housing (10); in, The support end cap (510) includes a first housing positioning structure (5001) configured to engage with a structure at the first position (P1) of the housing (10) to position the support end cap (510) relative to the housing (10) when inserted at the first position (P1).

3. The lamp assembly (100) according to claim 2, wherein the support member (50) further comprises a support body (520) connected to the support end cap (510) such that it is located between the circuit board extension (210) and the first seal (40), the support body (520) being configured to position the circuit board extension (210) and the first seal (40) relative to the housing (10).

4. The lamp assembly according to claim 3, wherein, A circuit board positioning structure (5002) is provided on the surface of the support body (520) facing the printed circuit board assembly (20), the circuit board positioning structure (5002) being configured to restrict the position of the circuit board extension (210) at least in the longitudinal and transverse directions of the support body (520).

5. The lamp assembly according to claim 3, wherein, A first sealing element positioning structure (5003) is provided on the surface of the support body (520) facing the first sealing element (40). The first sealing element positioning structure (5003) is configured to be fixedly connected to an external device so that the first sealing element (40) can be positioned relative to the support body (50). The external device includes a first injection mold for forming the first seal (40).

6. The lamp assembly according to claim 1, wherein, The wire harness assembly (30) includes: Multiple wire harnesses (310); A plug portion (320) is disposed at the end of the wire harness assembly (30) and configured to connect to the printed circuit board assembly (20) to connect the plurality of wire harnesses (310) to the printed circuit board assembly (20); A sealing ring (330) is located near the plug portion (320) and is configured to surround the plurality of wire harnesses (310); and A compression ring (340) is configured to be wrapped around the sealing ring (330) so that the sealing ring (330) presses against the plurality of wire harnesses (310).

7. The lamp assembly according to claim 6, wherein, The first seal (40) is formed of liquid silicone, and the sealing ring (330) is formed of solid silicone or rubber; and The first seal (40) extends from the first position (P1) of the housing (10) to the sealing ring (330) of the wire harness assembly (30) to bond with the sealing ring (330).

8. The lamp assembly according to claim 1, wherein, The housing (10) further includes a second position (P2), which is the end of the housing (10) in the first direction (D1); as well as The lamp assembly (100) also includes: A second seal (60) is configured to seal the second position (P2) of the housing (10); and An end cap (70) is disposed at the second position (P2) between the housing (10) and the second seal (60) and is configured to be inserted into the housing (10) at the second position (P2), the end cap (70) being configured to prevent the second seal (60) from entering the interior of the housing (10).

9. The lamp assembly according to claim 8, wherein, A second housing positioning structure (7001) is provided on the surface of the end cap (70) facing the housing (10). The second housing positioning structure (7001) is configured to cooperate with a structure at the second position (P2) of the housing (10) so as to position the end cap (70) relative to the housing (10) when inserted at the second position (P2); and A second sealing element positioning structure (7002) is provided on the surface of the end cap (70) facing away from the housing (10). The second sealing element positioning structure (7002) is configured to be fixedly connected to an external device so that the second sealing element (60) can be positioned relative to the end cap (70). The external device includes a second injection mold for forming the second seal (60).

10. The lamp assembly according to claim 2, in, The first position (P1) of the housing (10) is located at at least one of the first end, the second end, and the position between the first end and the second end in the first direction (D1) of the housing (10); The angle between the circuit board extension (210) of the printed circuit board assembly (20) and the housing (10) is 180 degrees, 90 degrees or 0 degrees.

11. The lamp assembly according to claim 10, wherein, The circuit board extension (210) includes a portion of a flexible circuit board (2001) extending outward from the housing (10) and a signal input circuit board (2002) soldered to the flexible circuit board (2001).

12. The lamp assembly according to claim 11, wherein, The support member (50) is connected to the signal input circuit board (2002) via a connecting member; The connecting component includes at least one of adhesive, snap-fit ​​structure, riveting structure and screw.

13. A method for manufacturing a lamp assembly, characterized in that, The method includes: Step S1: A housing (10) is prepared by an extrusion process along a first direction (D1) to accommodate a printed circuit board assembly (20) within the housing (10), and a portion of the printed circuit board assembly (20) extends outward from at least a first position (P1) of the housing (10), such that the printed circuit board assembly (20) includes a portion located inside the housing (10) and a circuit board extension portion (210) located outside the housing (10), wherein the circuit board extension portion (210) is connected to a wire harness assembly (30); and Step S2: Place a portion of the housing (10) at the first position (P1), the circuit board extension (210), and a portion of the wiring harness assembly (30) into a first injection mold to prepare a first seal (40).

14. The method according to claim 13, wherein, Step S2 includes: Step S21: After inserting the support end cap (510) into the housing (10) at the first position (P1), the portion of the housing (10) with the support end cap (510) at the first position (P1), the circuit board extension (210), and a portion of the wiring harness assembly (30) are placed into the first injection mold to prepare the first seal (40). Step S22: Place the circuit board extension (210) on the support body (520) connected to the support end cap (510), and connect the circuit board extension (210) to the support body (520) via a connecting member; and The first seal (40) is prepared by fixing the support body (520) to the first injection mold.

15. The method according to claim 13, further comprising: Step S3: Insert the end cap (70) into the housing (10) at the second position (P2); The second seal (60) is prepared by fixing the end cap (70) to the second injection mold, placing the portion of the housing (10) at the second position (P2) and the end cap (70) into the second injection mold.

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