LED lamp optical module with micro-prism reflective structure

Abstract

This invention discloses an LED lamp optical module with a microprism reflective structure, relating to the field of lighting equipment technology. The module includes: a substrate; LED beads disposed on the substrate; and a circuit board disposed on the surface of the substrate. The circuit board has a reflective surface treated with a high-reflectivity coating. The entire module utilizes a reflective mechanism between the substrate and the LED beads, employing a microprism structure on the inner wall of the cup structure to couple with the high-reflectivity circuit board to recover laterally scattered light. Simultaneously, the density and apex angle gradient changes of the microprism units eliminate uneven illuminance. The cup adjustment structure uses the heat generated by the LED beads to drive a double-layered micro-airbag, which, via a push rod and abutment rotation rod, drives the semi-circular cup for passive adaptive adjustment. A memory metal driving component finely adjusts the light output direction.

Description

Technical Field

[0001] This invention relates to the field of lighting equipment technology, specifically to an LED lamp optical module with a microprism reflective structure. Background Technology

[0002] LED lighting fixtures, with their advantages of energy saving, environmental friendliness, and long lifespan, have been widely used in commercial, industrial, and municipal lighting. Existing LED lighting fixtures typically include a substrate, LED chips mounted on the substrate, a circuit board, and secondary optical components (such as reflectors or refractors). In practical applications, the light emitted by the LED chips exhibits a Lambertian distribution, with approximately 30% of the side-scattered light reaching the surface of the circuit board.

[0003] Currently, the reflectivity of traditional circuit boards is generally low (approximately 60%-70%), resulting in a significant portion of lateral scattered light being absorbed by the circuit board or dissipating in ineffective directions, leading to wasted light energy. Although some high-end lighting fixtures use independent reflector cups or prism sheets, these reflectors and refractors are mostly designed in series, lacking coordinated coupling, resulting in significant interface reflection loss and a large size, making them difficult to adapt to the needs of ultra-thin lighting fixtures. In addition, the cup structure of existing lighting fixtures is mostly at a fixed angle, unable to be dynamically adjusted according to the actual working state of the LED chips (such as the drift in the emission angle caused by changes in heat generation), resulting in unstable luminous efficiency under different operating conditions. At the same time, traditional lighting fixtures still have significant shortcomings in terms of illuminance uniformity, glare control, intelligent dimming, and thermal management. Summary of the Invention

[0004] The purpose of this invention is to provide an LED lighting optical module with a microprism reflective structure to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an LED lamp optical module with a microprism reflective structure, comprising: substrate; LED beads are mounted on a substrate; A circuit board disposed on the surface of a substrate, the circuit board having a reflective surface treated with a high reflectivity coating; A reflective mechanism is installed between the circuit board and the LED beads to adjust the brightness of the LED beads after multiple refractions and reflections. The reflective mechanism includes a cup structure, a microprism structure, a reflective structure, and a cup adjustment structure. The bowl-cup structure is installed inside the cover installed outside the LED lamp bead, and includes four sets of semi-circular bowl-cups. The angle of the four sets of semi-circular bowl-cups can be adjusted relative to the light emission angle of the LED lamp bead. The microprism structure forms a microprism array located on the inner wall surface of the cup structure. The microprism array includes multiple microprism units. At least a portion of the microprism structure forms an optical gap with a preset angle between itself and the reflective surface of the circuit board. The microprism unit has an incident surface, a reflecting surface, and an exit surface. The side-scattered light emitted by the LED beads is refracted and / or reflected by the microprism unit and then guided to the reflective surface of the circuit board. After being reflected by the reflective surface, it is emitted from the microprism reflective layer. The reflective structure is installed on the top of the cup structure to receive the light emitted from the microprism reflective layer and form an angle-adjustable reflection. The bowl-cup adjustment structure is installed on the side of the semi-circular bowl-cup and is used to drive the semi-circular bowl-cup to adjust its angle according to the light emitted by the LED beads.

[0006] Preferably, a micro-adjustment component is installed at the bottom of the reflective structure, a memory metal driving component is installed inside the micro-adjustment component, and a circuit mounting plate is installed at the bottom of the micro-adjustment component.

[0007] Preferably, the bowl-cup adjustment structure includes: A mounting plate is installed on the bottom surface of the wiring mounting plate, and a heat conduction sheet is installed inside it; A double-layered micro-airbag, wherein the double-layered micro-airbag is configured as two sets stacked on top of each other, and its interior is filled with a high-boiling-point liquid and a low-boiling-point liquid, respectively. The cavity column has a push rod slidably connected to its outlet end, and a limit sleeve rod is slidably connected to the outside of the push rod.

[0008] Preferably, the side end of the limiting sleeve is rotatably connected to an abutting rotating rod, and the side end of the abutting rotating rod contacts the top of the outer wall of the semi-circular bowl.

[0009] Preferably, the connecting ends of the four sets of semi-circular bowls are equipped with flexible corrugated connectors, and the interior of the four sets of semi-circular bowls is equipped with flexible rings.

[0010] Preferably, the distribution density of the microprism units gradually increases from the center region to the edge region of the LED bead, and the prism apex angle of the microprism units gradually decreases from the center region to the edge region of the LED bead.

[0011] Preferably, the high-boiling-point liquid in the double-layer micro airbag is water or heat-conducting oil, and the low-boiling-point liquid is ethanol or acetone. The heat-conducting sheet conducts the heat generated by the LED beads to the double-layer micro airbag, causing the low-boiling-point liquid to vaporize and expand preferentially, pushing the push rod to move, and then adjusting the angle of the semi-arc cup by abutting the rotating rod.

[0012] Preferably, an external heat dissipation sleeve is installed on the outside of the substrate, and a power supply connector is connected to the bottom of the external heat dissipation sleeve.

[0013] Preferably, an outer protective shell is installed on the top of the outer heat dissipation sleeve, and a lens end is installed on the top of the outer protective shell.

[0014] Preferably, the power supply connector is equipped with an intelligent controller, which is electrically connected to the LED beads and is used to automatically adjust the drive current based on the ambient pedestrian density information to achieve self-learning dimming control.

[0015] Compared with the prior art, the beneficial effects of the present invention are: In this invention, a reflective mechanism is set between the substrate and the LED beads. The microprism structure on the inner wall of the cup structure forms a coupled optical system with the high-reflectivity circuit board. The side-scattered light emitted by the LED beads is refracted and totally reflected by the microprism units, then guided to the reflective surface of the circuit board. After further reflection, it exits from the microprism reflective layer, effectively recovering the side light wasted in traditional solutions and significantly improving the overall light efficiency. Simultaneously, the distribution density of the microprism units and the gradient change in prism apex angle from the center to the edge eliminate central hot spots and edge dark areas, significantly improving the uniformity of illumination on the light-emitting surface. The cup adjustment structure utilizes the heat generated by the LED beads themselves to drive the vaporization and expansion of the low-boiling-point liquid within the double-layered micro-airbag. This expansion, via a push rod and a contact rotating rod, causes the semi-circular cup to adaptively open or close, achieving passive dynamic angle adjustment. This ensures that the optical system always matches the actual emission angle of the LED beads. The memory metal driving component at the bottom of the reflective structure further fine-tunes the light emission direction according to temperature changes. In addition, the external heat dissipation sleeve and heat conduction plate work together to dissipate heat, the intelligent controller learns and adjusts the dimming based on the flow density of people, and the widened circuit board is designed to prevent creepage and leakage, which improves the module's light efficiency, uniformity, adaptability, energy saving effect and safety. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the main structure in this invention; Figure 2 This is a schematic diagram of the detached structure of the main body in this invention; Figure 3 This is a schematic diagram of the reflective mechanism in this invention; Figure 4 This is a schematic diagram showing the structural separation of the reflective mechanism in this invention; Figure 5 This is a partial structural schematic diagram of the reflective mechanism in this invention; Figure 6 In this invention Figure 5 A magnified structural diagram at point A; Figure 7 In this invention Figure 5 A magnified structural diagram at point B.

[0017] In the diagram: 100, outer protective shell; 110, substrate; 120, outer heat dissipation sleeve; 130, LED lamp bead; 140, reflective mechanism; 141, cover; 142, flexible ring; 143, cup structure; 144, microprism structure; 145, reflective structure; 146, circuit mounting plate; 147, fixing plate; 148, double-layer micro airbag; 149, cavity column; 1490, limiting sleeve rod; 1491, abutting rotation rod; 1492, memory metal driving component; 1493, micro-adjustment component; 1494, push rod; 200, lens end; 300, power supply connector. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Reference Figures 1-7 As shown: An LED lamp optical module with a microprism reflective structure includes: a substrate 110; LED beads 130 disposed on the substrate 110; a circuit board disposed on the surface of the substrate 110, the circuit board having a reflective surface treated with a high reflectivity coating; a reflective mechanism 140 disposed between the circuit board and the LED beads 130, used to adjust the luminance of the LED beads 130 after multi-stage refraction and reflection, the reflective mechanism 140 including a cup structure 143, a microprism structure 144, a reflective structure 145 and a cup adjustment structure; the cup structure 143 is disposed inside a cover 141 disposed outside the LED beads 130, including four sets of semi-circular cups, the angles of the four sets of semi-circular cups can be adjusted relative to the light emission angle of the LED beads 130; The microprism structure 144 forms a microprism array located on the inner wall surface of the cup structure 143. The microprism array includes multiple microprism units. At least a portion of the microprism structure 144 forms an optical gap with a preset angle between itself and the reflective surface of the circuit board. The microprism unit has an incident surface, a reflecting surface, and an exit surface. The side-scattered light emitted by the LED beads 130 is refracted and / or reflected by the microprism unit and then guided to the reflective surface of the circuit board. After being reflected by the reflective surface, it is emitted from the microprism reflective layer. The reflective structure 145 is installed on the top of the cup structure 143 to receive the light emitted from the microprism reflective layer and form an angle-adjustable reflection. The cup adjustment structure is correspondingly installed on the side end of the semi-circular cup to drive the semi-circular cup to adjust its angle according to the light emitted by the LED beads 130.

[0020] Specifically, the substrate 110 is made of a high thermal conductivity metal material, such as aluminum alloy or copper substrate. Its lower surface is used to mount the driving circuit, and its upper surface is used to support the LED beads 130 and related optical components. At least one LED bead 130 is fixedly disposed in the central area of ​​the substrate 110. The LED bead 130 adopts high luminous efficiency flip chip or regular chip package, and its emission angle has a Lambertian distribution characteristic, that is, the light intensity is strongest in the central area and gradually weakens towards the edge.

[0021] A circuit board is disposed on the upper surface of the substrate 110, that is, in the area surrounding the LED beads 130. The circuit board not only serves the function of providing power to the LED beads 130, but more importantly, its surface is treated with a high-reflectivity coating to form a smooth and highly reflective surface. This reflective surface can be achieved using processes such as white solder resist ink, silver plating, or titanium dioxide nano-coating, and its reflectivity can reach over 90%, enabling it to efficiently reflect incident light back to the light-emitting direction.

[0022] A reflector mechanism 140 is disposed between the LED bead 130 and the circuit board, specifically at the side of the LED bead 130. The reflector mechanism 140 has an overall annular or bowl-shaped structure, fitted around the LED bead 130. Its function is to refract, reflect, and converge the light emitted by the LED bead 130 in multiple stages, thereby effectively adjusting the light direction and intensity distribution. Specifically, the reflector mechanism 140 includes a bowl structure 143, a microprism structure 144, a reflection structure 145, and a bowl adjustment structure.

[0023] Furthermore, the cup structure 143 is installed inside a transparent or opaque cover 141 outside the LED bead 130. The cover 141 is a hollow cylinder, with its bottom fixed to the substrate 110 and its top open. The cup structure 143 is composed of four sets of semi-circular cups, each with a concave arc surface. The four sets of semi-circular cups are arranged in a circular array around the central axis of the LED bead 130. The angle of the four sets of semi-circular cups can be dynamically adjusted according to the actual light emission angle of the LED bead 130. For example, when the light emission angle of the LED bead 130 is large, the semi-circular cups can open outward to capture more lateral light; when the light emission angle is small, the semi-circular cups can close inward to avoid blocking the main beam.

[0024] A microprism structure 144 is disposed on the inner wall surface of the bowl-shaped structure 143, i.e., on the side facing the LED bead 130. The microprism structure 144 is composed of a microprism array, and each microprism unit in the array has a precisely designed incident surface, reflecting surface, and exit surface. At least a portion of the microprism structure 144, especially the area near the bottom, maintains a preset optical gap with the reflective surface of the circuit board. The existence of this gap allows light to undergo multiple reflections between the microprism structure 144 and the circuit board, thereby achieving effective coupling of the optical path.

[0025] When the LED bead 130 emits light, the side-scattered light it emits first enters the incident surface of the microprism unit. After one or more refractions inside the microprism, it reaches the reflecting surface and undergoes total internal reflection, being guided to the reflective surface of the circuit board below. The reflective surface of the circuit board reflects the received light again, causing it to pass upward through the microprism structure 144 and exit from its exit surface. Through the multi-segment light path of microprism refraction, circuit board reflection, and microprism exit, the side-scattered light that would otherwise be absorbed by the circuit board or dissipated in an ineffective direction is efficiently recovered and guided to the main light output direction.

[0026] At the top of the bowl-shaped structure 143, at the end furthest from the LED bead 130, there is a reflective structure 145. The reflective structure 145 is ring-shaped or disc-shaped, and its lower surface is a highly reflective curved surface. It is used to receive the light emitted from the microprism structure 144 and perform a second angle adjustment and reflection on it, so that the light is finally emitted outward at a preset light emission angle.

[0027] The cup adjustment structure is installed on the side of each set of semi-circular cups. Its function is to sense the working status of the LED beads 130, especially the change in heat generation, and drive the semi-circular cups to adjust their angle accordingly, so as to dynamically adapt to different light-emitting conditions.

[0028] Preferred, such as Figure 7 As shown, a micro-adjustment component 1493 is installed at the bottom of the reflective structure 145, a memory metal drive component 1492 is installed inside the micro-adjustment component 1493, and a circuit mounting plate 146 is installed at the bottom of the micro-adjustment component 1493.

[0029] Specifically, the shape memory metal driver 1492 is made of a nickel-titanium alloy or a copper-based shape memory alloy with shape memory effect. When the ambient temperature or the operating temperature of the LED bead 130 changes, the shape memory metal driver 1492 undergoes a reversible phase transition, resulting in specific deformations, such as elongation or contraction. The resulting deformation drives the micro-adjustment component 1493 to deflect the reflective structure 145 by a small angle, thereby achieving fine adjustment of the emitted light direction. The bottom of the micro-adjustment component 1493 is fixedly mounted on the circuit mounting plate 146, which serves the dual purpose of fixing the overall structure and carrying the circuit.

[0030] Preferred, such as Figure 6 As shown, the cup adjustment structure includes: a fixed plate 147, which is installed on the bottom surface of the circuit mounting plate 146 and has a heat conduction sheet installed inside; a double-layer micro airbag 148, which is configured as two sets stacked on top of each other, and is filled with a high-boiling-point liquid and a low-boiling-point liquid respectively; a cavity column 149, whose outlet end is slidably connected to a push rod 1494, and the outside of the push rod 1494 is slidably connected to a limit sleeve rod 1490.

[0031] The fixing plate 147 is mounted on the bottom surface of the circuit mounting plate 146 and is made of a metal material with good thermal conductivity, such as copper or aluminum. A heat conduction sheet is embedded inside the fixing plate 147. One end of the heat conduction sheet is in contact with the heat conduction path on the substrate 110 or the circuit board, and the other end extends to the bottom of the double-layer micro airbag 148, which is used to efficiently conduct the heat generated by the LED beads 130 during operation to the airbag area.

[0032] The double-layered micro-airbag 148 is positioned above the fixed plate 147 and consists of two stacked micro-airbags. The upper airbag is filled with a low-boiling-point liquid, such as ethanol or acetone, while the lower airbag is filled with a high-boiling-point liquid, such as water or heat transfer oil. The two liquids have significantly different boiling points: the low-boiling-point liquid typically boils between 60-80°C, while the high-boiling-point liquid boils above 100°C. When heat is conducted to the airbag, the low-boiling-point liquid preferentially vaporizes and expands, resulting in a larger volume change; while the high-boiling-point liquid remains liquid or expands only slightly, acting as a buffer and stabilizing pressure.

[0033] The cavity column 149 is a hollow cylinder, with its bottom communicating with or in contact with the upper surface of the double-layered micro-airbag 148. A push rod 1494 is slidably connected to its top outlet end. A limiting sleeve 1490 is sleeved on the outside of the push rod 1494, and the limiting sleeve 1490 is fixed to the top of the cavity column 149, guiding and limiting the axial movement of the push rod 1494. When the low-boiling-point liquid inside the double-layered micro-airbag 148 vaporizes and expands, the airbag volume increases, pushing the push rod 1494 inside the cavity column 149 upward.

[0034] Preferred, such as Figure 6 As shown, the side end of the limiting sleeve 1490 is rotatably connected to the abutting rotating rod 1491, and the side end of the abutting rotating rod 1491 is in contact with the top of the outer wall of the semi-circular bowl.

[0035] Specifically, a pivoting rotating rod 1491 is rotatably connected to the side end of the limiting sleeve 1490, near the semi-circular cup, via a pivot or hinge. The pivoting rotating rod 1491 is L-shaped or straight, with one end rotatably connected to the limiting sleeve 1490 and the other end abutting against the top or bottom of the outer wall of the semi-circular cup. When the pushing rod 1494 moves upward, the top of the pushing rod 1494 contacts the middle or end of the pivoting rotating rod 1491, causing the pivoting rotating rod 1491 to deflect around its pivot axis, thus converting the upward linear motion into a lateral thrust on the top of the outer wall of the semi-circular cup. Under this thrust, the top of the semi-circular cup opens outward, thereby changing the cup's focusing angle.

[0036] Preferred, such as Figure 5 As shown, the connecting ends of the four sets of semi-circular bowls are all equipped with flexible corrugated connectors, and the interior of the four sets of semi-circular bowls is equipped with flexible rings 142.

[0037] Specifically, to ensure that the four sets of semi-circular cups can move synchronously without interference during angle adjustment, flexible corrugated connectors are installed at the connecting ends of adjacent sets of semi-circular cups. These flexible corrugated connectors are made of high-temperature resistant silicone or polyurethane elastomers, and their surfaces have a wavy or accordion-like corrugated structure. They can freely expand and contract when the semi-circular cups open or close, while also serving to prevent dust and light leakage and maintain structural continuity.

[0038] Furthermore, a flexible ring 142 is installed inside the four sets of semi-circular cups, specifically on the side closest to the LED beads 130. The flexible ring 142, also made of elastic material, surrounds the LED beads 130 and conforms to the inner wall of the four sets of semi-circular cups. The flexible ring 142 adapts to the angle of the semi-circular cups, maintaining coverage of the area surrounding the LED beads 130 and preventing light leakage from the gaps between the cups. Secondly, the inner surface of the flexible ring 142 can be further coated with a high-reflectivity coating or a microprism structure 144 to improve the efficiency of lateral light recovery.

[0039] Preferred, such as Figure 3 As shown, the distribution density of the microprism units gradually increases from the center region to the edge region of the LED bead 130, and the prism apex angle of the microprism units gradually decreases from the center region to the edge region of the LED bead 130.

[0040] Specifically, the distribution density of microprism units gradually increases from the central region of the LED bead 130 (the area directly opposite the light-emitting surface of the LED bead 130) towards the edge region (the area away from the side wall of the semi-circular cup). That is, the microprism units are more sparsely arranged near the center of the LED bead 130, and more densely arranged near the edge of the semi-circular cup. Overall, because the light in the central region of the LED bead 130 is inherently stronger, fewer microprisms are needed for refraction and recovery; while the light in the edge region is weaker and at a larger angle, requiring more microprism units for capture and guidance.

[0041] Simultaneously, the prism apex angle of the microprism unit gradually decreases from the center to the edge. A larger prism apex angle is suitable for deflecting light rays incident at large angles, while a smaller prism apex angle is suitable for deflecting light rays incident at small angles. Through the gradient change in apex angle, light rays with different incident angles can obtain optimal refraction and reflection efficiency in the corresponding microprism unit, thereby improving the overall uniformity of illumination on the light-emitting surface.

[0042] Preferred, such as Figure 6 As shown, the high-boiling-point liquid in the double-layer micro airbag 148 is water or heat-conducting oil, and the low-boiling-point liquid is ethanol or acetone. The heat-conducting sheet conducts the heat generated by the LED bead 130 to the double-layer micro airbag 148, causing the low-boiling-point liquid to vaporize and expand preferentially, pushing the push rod 1494 to move, and then adjusting the angle of the semi-arc cup by abutting the rotating rod 1491.

[0043] Furthermore, the high-boiling-point liquid in the double-layered micro-airbag 148 is preferably water or thermally conductive oil, with a boiling point typically above 100°C; the low-boiling-point liquid is preferably ethanol, with a boiling point of approximately 78°C, or acetone, with a boiling point of approximately 56°C. The two liquids are respectively encapsulated in two independent airbag chambers stacked vertically, separated by a thermally conductive membrane.

[0044] This allows the heat generated by the LED beads 130 after prolonged operation to be conducted through the substrate 110 and the circuit mounting plate 146 to the heat conduction sheet within the fixing plate 147. The heat conduction sheet further transfers the heat to the bottom of the double-layer micro airbag 148. Because the low-boiling-point liquid has a lower boiling point, it preferentially absorbs heat and vaporizes, producing a large amount of steam, causing the upper airbag to expand rapidly. This expansion of the upper airbag compresses the lower high-boiling-point liquid airbag, increasing the overall height of the airbag. The double-layer micro airbag 148 is integrally molded from multi-layer co-extruded composite polymer material, with a high-temperature resistant barrier layer coated on the inner wall, ensuring no leakage or mixing of the two liquids under long-term thermal cycling conditions.

[0045] Next, the increase in height of the double-layered micro-airbag 148 will push the push rod 1494 inside the cavity column 149 to move. The side end of the push rod 1494 is slidably engaged with the limiting sleeve 1490, which constrains the direction of movement of the push rod 1494, ensuring that it moves linearly along the axial direction. As the push rod 1494 continues to move, its tip will contact the middle of the abutting rotating rod 1491 and apply an upward thrust, causing the abutting rotating rod 1491 to deflect around its rotational connection point with the limiting sleeve 1490. This, in turn, causes the other end of the abutting rotating rod 1491 to apply a lateral thrust to the top of the outer wall of the semi-circular cup, pushing the semi-circular cup to adjust inward / outward. The cup adjustment structures corresponding to the four sets of semi-circular cups are designed with the same materials and size parameters. Each double-layer micro airbag 148 receives heat through the same heat conduction path, ensuring that the four sets of semi-circular cups open or close synchronously under the same heating conditions, thus maintaining the symmetry of the optical system.

[0046] Based on this process, the heat generated by the LED bead 130 is directly converted into an adjustment range for the angle of the semi-circular cup. That is, the greater the heat generation, the more intense the vaporization of the low-boiling-point liquid, and the larger the opening angle of the semi-circular cup. Conversely, when the heat generation decreases, the low-boiling-point liquid condenses and contracts, and the semi-circular cup gradually closes. The overall reliability is high and the response is timely.

[0047] The height of the cavity column 149 and the stroke of the push rod 1494 are designed to match the rated heat output of the LED bead 130 and the expansion volume of the airbag, ensuring that the push rod 1494 has sufficient stroke to adjust the semi-circular cup to the maximum angle under maximum heat output.

[0048] Preferred, such as Figure 2 As shown, an external heat dissipation sleeve 120 is installed on the outside of the substrate 110, and a power supply connector 300 is connected to the bottom of the external heat dissipation sleeve 120.

[0049] Specifically, the outer heat sink 120 is made of extruded aluminum alloy or copper, and its outer surface has multiple axially extending heat dissipation fins to increase the heat dissipation area. The inner wall of the outer heat sink 120 is tightly fitted to the outer wall of the substrate 110, and thermal grease can be applied between them to reduce contact thermal resistance. The bottom of the outer heat sink 120 is connected to a power supply connector 300 via a threaded or snap-fit ​​structure. The power supply connector 300 integrates a power drive circuit to convert external AC or DC power into a constant current power supply suitable for the operation of the LED beads 130, and is electrically connected to the circuit board via wires.

[0050] Preferred, such as Figure 1 and Figure 2 As shown, an outer protective shell 100 is installed on the top of the outer heat dissipation sleeve 120, and a lens end 200 is installed on the top of the outer protective shell 100.

[0051] The outer housing 100 is made of engineering plastic or aluminum alloy, serving to protect the internal optical components and provide dust and water resistance. A lens end 200 is mounted on the top of the outer housing 100, i.e., the light-emitting surface. The lens end 200 is typically made of high-transmittance tempered glass or polycarbonate material, and its surface can be further treated with an anti-reflective coating or frosted finish to optimize light emission and anti-glare performance.

[0052] Preferred, such as Figure 1 and Figure 2 As shown, the power supply connector 300 is equipped with an intelligent controller, which is electrically connected to the LED lamp bead 130. The controller is used to automatically adjust the drive current based on the ambient pedestrian density information to achieve self-learning dimming control.

[0053] Specifically, the intelligent controller can be installed separately inside the power supply connector 300 as needed, or installed on an external interface according to the modules of the overall device. The intelligent controller includes a microprocessor, wireless communication such as Bluetooth or Wi-Fi, and an environmental sensor interface. The intelligent controller is electrically connected to the driving circuit of the LED beads 130, and can monitor environmental parameters in real time, such as pedestrian density, ambient light intensity, and time. Based on the feedback from the environmental sensors, it automatically adjusts the driving current of the LED beads 130, thereby realizing self-learning dimming control.

[0054] In scenarios such as garages or corridors, the intelligent controller can acquire real-time pedestrian density information through connected cameras or infrared sensors. When pedestrian traffic is high, it automatically increases the driving current of the LED beads (130W) to increase brightness, while automatically reducing the driving current and entering energy-saving mode when pedestrian traffic is low or there is no activity. The intelligent controller also has a self-learning function, capable of recording pedestrian traffic patterns at different times to develop personalized dimming strategies, further improving energy efficiency.

[0055] The usage and working principle of this device are as follows: First, the power supply connector 300 is connected to an external power source. Its internal power drive circuit converts AC power into constant current DC power, which is then supplied to the LED beads 130 through the circuit board. The LED beads 130 are lit and begin to emit light. Due to the light-emitting characteristics of the LED chip, its light emission follows a Lambertian distribution. At this time, approximately 60% of the light is emitted upwards in a near-vertical direction, i.e., the main beam, while approximately 30% of the light is emitted laterally at a large angle, i.e., side-scattered light. The remaining approximately 10% of the light is absorbed by the LED bead 130 itself or by the circuit board.

[0056] At this time, the reflective mechanism 140 is in the initial position, that is, the four sets of semi-circular cups are in a closed state, and the microprism structure 144 on the inner wall of the semi-circular cups maintains a preset optical gap with the reflective surface of the circuit board.

[0057] The small-angle main beam emitted by the LED beads 130, i.e., the light in the central region, propagates almost vertically upwards, passing sequentially through the internal space of the cover 141, the top opening of the cup structure 143, and the central through-hole of the reflective structure 145, finally exiting from the lens end 200 at the top of the outer protective shell 100, directly illuminating the target area. This portion of the light undergoes almost no reflection or refraction, resulting in minimal light energy loss. The reflective structure 145 is a ring-shaped structure with a central through-hole through which the main beam exits directly, while the side-recovered light is reflected from the lower surface before exiting.

[0058] Next, the side-scattered light emitted by the LED bead 130, i.e., the large-angle light, propagates outward and first encounters the microprism structure 144 on the inner wall of the cup structure 143. This light enters the interior of the microprism unit from its incident surface. Due to the precisely designed geometry of the microprism unit, the light undergoes one or more refractions inside the microprism before reaching the reflecting surface. When the incident angle is greater than the critical angle, the light undergoes total internal reflection on the reflecting surface and is guided downwards to the reflective surface of the circuit board.

[0059] Meanwhile, the reflective surface of the circuit board has a high-reflectivity coating, which reflects the received light upwards again. This reflected light re-enters the microprism structure 144, exits from the exit surface of the microprism unit, and propagates upwards. At this point, the side-scattered light that would otherwise be wasted is successfully recovered and propagates upwards along with the main beam.

[0060] Next, the light emitted from the microprism structure 144, including the recovered side light and part of the main beam, reaches the reflector structure 145 at the top of the cup structure 143. The lower surface of the reflector structure 145 is a highly reflective curved surface, and its radius of curvature and reflection angle can be customized according to design requirements. The light undergoes a second reflection on the surface of the reflector structure 145, and its emission angle is further narrowed or widened to adapt to different lighting needs, such as narrow-beam spotlights or wide-beam panel lights.

[0061] At the bottom of the reflective structure 145, the memory metal drive 1492 inside the micro-adjustment component 1493 undergoes slight deformation according to changes in ambient temperature or lamp bead operating temperature, thereby driving the reflective structure 145 to make a slight angular deflection, achieving precise calibration of the light output direction.

[0062] While the aforementioned optical path is operating, the bowl-cup adjustment structure begins to function. Specifically, the LED beads 130 generate heat after prolonged operation. This heat is conducted through the substrate 110 and the circuit mounting plate 146 to the heat conduction sheet within the fixing plate 147, and then transferred by the heat conduction sheet to the double-layer micro-airbag 148. The low-boiling-point liquid, ethanol, or acetone, within the double-layer micro-airbag 148 preferentially absorbs heat and vaporizes, causing the overall height of the double-layer micro-airbag 148 to increase. The expansion of the double-layer micro-airbag 148 pushes the push rod 1494 within the cavity column 149 upward. The upper end of the push rod 1494 pushes the abutment rotating rod 1491 to deflect, and the other end of the abutment rotating rod 1491 applies a lateral thrust to the bottom of the outer wall of the semi-circular bowl-cup, causing the semi-circular bowl-cup to open outward.

[0063] The greater the heat generated, the wider the opening angle of the semi-circular cup, thus capturing a larger angle of lateral scattered light. When the power of the lamp bead decreases or it works intermittently, the heat generated decreases, the low-boiling-point liquid condenses and contracts, and the semi-circular cup gradually closes, returning to its initial state.

[0064] This ensures that the angle of the bowl-shaped structure 143 always matches the actual working state of the LED beads 130, achieving dynamic optimal light efficiency.

[0065] During the operation of the entire lamp, the intelligent controller inside the power supply connector 300 continuously monitors environmental parameters, such as pedestrian density and ambient light intensity obtained through external environmental sensors. This allows the intelligent controller to adjust the driving current of the LED beads 130 in real time based on the dimming curve formed by feedback from the external environmental sensors or through self-learning. In a garage scenario, when a vehicle or pedestrian is detected, the intelligent controller increases the driving current to the rated value to achieve high-brightness lighting. When no activity is detected for an extended period, the driving current is reduced to 20%-30%, maintaining basic lighting while significantly saving energy. The intelligent controller also records pedestrian flow patterns at different times of day, continuously optimizing the dimming strategy to achieve a smart lighting experience.

[0066] Throughout the operation, the heat dissipation fins of the outer heat sink 120 continuously dissipate the heat conducted from the substrate 110 into the surrounding air, ensuring that the junction temperature of the LED beads 130 is always controlled within a safe range. The outer housing 100 and the lens end 200 protect the internal optical components from dust, moisture and impact, while the anti-reflection coating treatment of the lens end 200 further reduces the reflection loss of the light-emitting surface.

[0067] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An LED lamp optical module with a microprism reflective structure, characterized in that, include: substrate(110); LED beads (130) are disposed on a substrate (110); A circuit board disposed on the surface of a substrate (110), the circuit board having a reflective surface treated with a high reflectivity coating; A reflector mechanism (140) is installed between the circuit board and the LED beads (130) to adjust the brightness of the LED beads (130) after multiple refractions and reflections. The reflector mechanism (140) includes a cup structure (143), a microprism structure (144), a reflection structure (145), and a cup adjustment structure. The bowl-cup structure (143) is installed inside the cover (141) installed outside the LED lamp bead (130), and includes four sets of semi-circular bowl cups. The angle of the four sets of semi-circular bowl cups can be adjusted relative to the light emission angle of the LED lamp bead (130). The microprism structure (144) forms a microprism array located on the inner wall surface of the cup structure (143). The microprism array includes multiple microprism units. At least a portion of the microprism structure (144) forms an optical gap with a preset angle between itself and the reflective surface of the circuit board. The microprism unit has an incident surface, a reflecting surface, and an exit surface. The side-scattered light emitted by the LED beads (130) is refracted and / or reflected by the microprism unit and then guided to the reflective surface of the circuit board. After being reflected by the reflective surface, it is emitted from the microprism reflective layer. The reflective structure (145) is installed on the top of the cup structure (143) to receive the light emitted from the microprism reflective layer and form an angle-adjustable reflection. The bowl-cup adjustment structure is installed on the side of the semi-circular bowl-cup and is used to drive the semi-circular bowl-cup to adjust its angle according to the light emitted by the LED beads (130).

2. The LED lamp optical module with a microprism reflective structure according to claim 1, characterized in that: The bottom of the reflective structure (145) is provided with a micro-adjustment component (1493), the inside of the micro-adjustment component (1493) is provided with a memory metal drive component (1492), and the bottom of the micro-adjustment component (1493) is provided with a circuit mounting plate (146).

3. The LED lamp optical module with a microprism reflective structure according to claim 1, characterized in that: The bowl / cup adjustment structure includes: A fixing plate (147) is installed on the bottom surface of the wiring mounting plate (146), and a heat conduction sheet is installed inside it; The double-layer micro airbag (148) is configured as two sets stacked on top of each other, and its interior is filled with a high-boiling-point liquid and a low-boiling-point liquid respectively. The cavity column (149) has a push rod (1494) slidably connected to its outlet end, and the push rod (1494) is externally slidably connected to a limit sleeve rod (1490).

4. The LED lamp optical module with a microprism reflective structure according to claim 3, characterized in that: The side end of the limiting sleeve (1490) is rotatably connected to an abutting rotating rod (1491), and the side end of the abutting rotating rod (1491) is in contact with the top of the outer wall of the semi-circular bowl.

5. The LED lamp optical module with a microprism reflective structure according to claim 1, characterized in that: The connecting ends of the four sets of semi-circular bowls and cups are all equipped with flexible corrugated connectors, and the interior of the four sets of semi-circular bowls and cups is equipped with a flexible ring (142).

6. The LED lamp optical module with a microprism reflective structure according to claim 1, characterized in that: The distribution density of the microprism units gradually increases from the center region of the LED beads (130) to the edge region, and the prism apex angle of the microprism units gradually decreases from the center region of the LED beads (130) to the edge region.

7. The LED lamp optical module with a microprism reflective structure according to claim 3, characterized in that: The high-boiling-point liquid in the double-layer micro airbag (148) is water or heat-conducting oil, and the low-boiling-point liquid is ethanol or acetone. The heat-conducting sheet conducts the heat generated by the LED beads (130) to the double-layer micro airbag (148), causing the low-boiling-point liquid to vaporize and expand preferentially, pushing the push rod (1494) to move, and then adjusting the angle of the semi-arc cup by abutting the rotating rod (1491).

8. The LED lamp optical module with a microprism reflective structure according to claim 1, characterized in that: An external heat dissipation sleeve (120) is installed on the outside of the substrate (110), and a power supply connector (300) is connected to the bottom of the external heat dissipation sleeve (120).

9. The LED lamp optical module with a microprism reflective structure according to claim 8, characterized in that: The top of the outer heat dissipation sleeve (120) is provided with an outer protective shell (100), and the top of the outer protective shell (100) is provided with a lens end (200).

10. The LED lamp optical module with a microprism reflective structure according to claim 8, characterized in that: The power supply connector (300) is equipped with an intelligent controller at its internal or external interface. The intelligent controller is electrically connected to the LED beads (130) and is used to automatically adjust the driving current based on the ambient pedestrian density information to achieve self-learning dimming control.

Images