A circuit board, a lens module and a vehicle lamp

Abstract

A kind of circuit board, light source and reflector bowl are provided above the circuit board, the circuit board is arranged at a certain angle with horizontal plane, so that along the direction of light irradiation or reflection of light source, the circuit board extends upwardly at an angle, the front end edge position of the circuit board is provided with a light blocking part, the light blocking part is provided with a concave notch, the center of light source, the center of reflector bowl and the center of the notch are in the same vertical plane, and the upper profile line of the notch forms the bright-dark cutoff line of light pattern.To ensure the stability of the irradiation area of light pattern, it is necessary to reduce the light in non-irradiation area, especially the light above the cutoff line of light pattern, this part of light is easy to enter the glasses of the driver of the oncoming vehicle, interfere with the driving vision, therefore, as far as possible to reduce this part of light, the concave notch of the application can reduce the light at the edge position, so that the edge position of the light pattern has higher resolution, and can reduce the irregular stray light at the edge, form sharp light pattern cutoff line, reduce the visual interference to the oncoming driver, increase driving safety.

Description

Technical Field

[0001] This application relates to the field of automotive lighting technology, and more particularly to a circuit board, a lens module, and an automotive lighting system. Background Technology

[0002] Currently, traditional vehicle headlights mainly rely on independent metal light shields for low beam pattern control, which has the following problems: additional assembly processes are required, increasing production costs; the positioning accuracy of the light shield is affected by assembly, resulting in complex beam patterns; multi-level light shielding structures are required, occupying a large space; and metal parts are prone to deformation under high-temperature environments, affecting beam pattern accuracy.

[0003] In the design of automotive lighting optical systems, the integration of the light-pattern baffle (i.e., the light-shielding structure) with the radiator or reflector is a key technological direction. Currently, there are three main integration methods: the light-pattern baffle is attached to the radiator, the radiator is integrated as a single unit, or the light-pattern baffle is attached to the reflector. Although these solutions meet functional requirements to a certain extent, they still have several technical disadvantages, which are analyzed in detail below:

[0004] 1. The solution of attaching the light pattern baffle to the radiator. This solution uses a mechanical fastening method to fix the baffle to the surface of the radiator and uses the support structure of the radiator to achieve the light-shielding function. The baffle is usually made of metal or composite material and has the functions of both light shielding and heat dissipation. The following defects may exist: (1) The contact surface between the baffle and the radiator needs to take into account both mechanical fixation and heat conduction, but the fastening structure may increase the interface thermal resistance due to loose contact, which will affect the heat dissipation efficiency. (2) Under long-term high temperature environment, the metal baffle and the radiator are prone to deformation due to the difference in thermal expansion coefficient, which will cause the fastening to loosen or shift, thereby affecting the light pattern accuracy (such as the offset of the light and dark cut-off line). (3) The baffle needs to cover the surface of the radiator, which may increase the overall weight and occupy space, affecting the compact design of the headlight. For example, the integrated radiator optimizes the structure through 3D printing, but the additional baffle may offset its lightweight advantage.

[0005] 2. The integrated solution of light-shielding baffle and heat sink is to design the baffle and heat sink as a single component through casting, stamping or additive manufacturing technology, reducing assembly links and improving structural strength. It may have the following defects: (1) The integrated solution needs to take into account the optical accuracy of the light-shielding structure and the thermodynamic performance of the heat sink, which requires extremely high process. For example, 3D printed heat sink adopts a very small curved surface design. If the integrated baffle is used, the matching between the heat sink fins and the light-shielding surface needs to be optimized, which significantly increases the design difficulty and cost. (2) If the integrated structure is damaged locally (such as the baffle deformation or the heat sink failure), the whole structure needs to be replaced, which greatly increases the maintenance cost. For example, SSD heat sink adopts a modular design, while the integrated solution lacks such flexibility. (3) The heat sink needs to be made of high thermal conductivity material (such as aluminum), while the baffle needs to be made of low reflectivity material (such as matte coating). Material selection needs to be compromised, which may lead to compromise on heat dissipation efficiency or optical performance.

[0006] 3. The solution of attaching the light-pattern baffle to the reflector bowl, where the baffle is directly fixed to the edge of the reflector bowl and the curved structure of the reflector bowl is used to achieve the light-shielding function, is commonly found in reflective vehicle headlight designs. The following defects may exist: (1) The fit between the baffle and the reflector bowl needs to be precisely controlled at the angle, otherwise the reflected light path may be offset, resulting in glare or blurred cut-off line. The reflector bowl needs to adjust the lens balance, which indirectly reflects the complexity of optical matching. (2) The reflector bowl is exposed to high temperature environment (such as LED or HID light source) for a long time. If the baffle material is not heat resistant enough (such as ordinary plastic), it is easy to deform or age. For example, vacuum coating equipment requires corrosion resistant materials, but the reflector bowl integrated baffle may face similar challenges. (3) The fastening structure may damage the seal of the reflector bowl, leading to the intrusion of water vapor or dust. For example, imported sealant is used to fix the lens, but the baffle fastening is difficult to achieve the same sealing effect.

[0007] Chinese patent application CN222047478U discloses a circuit board, a vehicle headlight module, and a vehicle headlight. The circuit board can be processed by edge cutting to directly form a light-dark cutoff line structure, eliminating the need for additional light-shielding parts or structures in the headlight module to form the light-dark cutoff line. However, the edges are all designed to bulge outwards, resulting in a light pattern with a lot of stray light. Furthermore, the cutoff line shape is fixed and cannot be dynamically adjusted, limiting functional expandability as light shielding is achieved only through a single layer of circuit board. Utility Model Content

[0008] This application provides a circuit board, a lens module, and a vehicle lamp to at least solve one of the above-mentioned technical problems existing in the prior art.

[0009] According to the first aspect of this application, a circuit board is provided, which works in conjunction with a light source and a reflector. The circuit board is tilted at a certain angle relative to the horizontal plane, so that the circuit board extends upward along the direction of light irradiation or reflection from the light source. A light-blocking part is provided at the front edge of the circuit board, and the light-blocking part has a concave notch. The center of the light source, the center of the reflector and the center of the notch are in the same vertical plane, and the upper contour line of the notch forms the light cutoff line of the light pattern.

[0010] Compared with the prior art, the circuit board of this application has the following advantages:

[0011] Since real-world light sources are not point sources and have a certain volume, they cannot be fully focused or have completely parallel illumination directions after being reflected by the reflector bowl. It is difficult to control the light at the edges well. To ensure the stability of the illumination area of ​​the light pattern, it is necessary to reduce the light in the non-illumination areas, especially the light above the light pattern cutoff line. This part of the light can easily enter the glasses of oncoming drivers and interfere with their driving vision. Therefore, it is necessary to minimize this part of the light. The concave notch of this application can reduce the light at the edges, making the light pattern edge position more distinguishable, and can also reduce irregular stray light at the edges, forming a sharp light pattern cutoff line, reducing interference with the vision of oncoming drivers, and increasing driving safety.

[0012] According to a second aspect of this application, a lens module is provided, including the aforementioned circuit board and a lens. The reflector bowl has an elliptical inner profile in its vertical cross-section, with the light source located at the first focal point of the ellipse. The light emitted from the light source is reflected by the reflector bowl and reaches a notch at the edge of the circuit board. The second focal point of the ellipse is located at the center of the notch, and the focal point of the lens is also located at the center of the notch. This design ensures that the second focal point coincides with the focal point of the lens, allowing the lens to convert converging light into parallel light. The light-blocking portion forms a sharp cutoff line, making passing safer.

[0013] According to a third aspect of this application, a lens module is provided, including a circuit board, a reflector, a light source, and a lens. The light source and the reflector are located above the circuit board. The circuit board is tilted at a certain angle relative to the horizontal plane, so that it extends upward along the direction of light illumination or reflection from the light source. A light-blocking part is provided at the front edge of the circuit board, and the light-blocking part is provided with a light-blocking plate. The outer contour of the light-blocking plate can block part of the light reaching the lens, forming a light-dark cutoff line of the light pattern. In this way, the light-blocking plate can be fixed to the circuit board by welding and then the outer contour line is processed, which can improve the accuracy of the outer contour line, and different light pattern cutoff lines can be set as needed.

[0014] In one embodiment, the light-blocking plate is made of shape memory alloy or fixed to the support arm via a shape memory alloy structure, and the support arm is fixed to the circuit board. This design can form cutoff lines of different heights, which can be adjusted according to different road conditions or driving situations. For example, when turning right, the right side of the vehicle is higher than the left side, and the light-blocking plate also needs to be higher on the right side than on the left side. After refraction by the lens, an inverted cutoff line is formed, making the cutoff line close to a horizontal position.

[0015] In one embodiment, the support arm includes a left arm and a right arm, which are mounted at the same height and spaced apart. This design facilitates independent control of the left and right arms.

[0016] In one embodiment, the shape memory alloy structure is a rhombus-shaped shape memory metal sheet, which includes a first metal sheet, a second metal sheet, a third metal sheet, and a fourth metal sheet. The first metal sheet is directly connected to the second metal sheet, the third metal sheet is directly connected to the fourth metal sheet, and the second metal sheet is directly or indirectly connected to the third metal sheet. The angle between the first metal sheet and the second metal sheet is equal to the angle between the third metal sheet and the fourth metal sheet. At room temperature, the angle between the first metal sheet and the second metal sheet is equal to the angle between the third metal sheet and the fourth metal sheet (the first angle). When heated to a higher temperature, the angle between the first metal sheet and the second metal sheet is equal to the angle between the third metal sheet and the fourth metal sheet (the second angle). The first angle may be greater than or less than the second angle, thus allowing the height of this position to change. By setting the same rhombus-shaped shape memory metal sheet on the left and right arms, the height of the light cutoff line can be adjusted.

[0017] In one embodiment, the shape memory alloy structure is an arc-shaped shape memory metal sheet, comprising a left shape memory metal sheet and a right shape memory metal sheet, which are mirror-symmetrical. The upper ends of the left and right shape memory metal sheets are electrically connected. The left shape memory metal sheet has a left terminal, and the right shape memory metal sheet has a right terminal. Applying a certain voltage between the left and right terminals heats the left and right shape memory metal sheets. This method is similar to the previous method, except that the shape of the metal sheets is different; the arc shape facilitates processing.

[0018] In one embodiment, both the left and right arms are provided with the same arc-shaped or rhomboid shape memory metal sheet. This symmetrical arrangement facilitates control.

[0019] In one embodiment, the light-blocking plate includes an arc-shaped plate and a base plate, with the arc surface of the arc-shaped plate facing the light source, and the left and right arms fixed to the lower end of the base plate. This design avoids light leakage and reduces stray light.

[0020] According to a fourth aspect of this application, a vehicle light is provided, including the above-described lens module and a heat sink.

[0021] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of this application, nor is it intended to limit the scope of this application. Other features of this application will become readily apparent from the following description. Attached Figure Description

[0022] The above and other objects, features, and advantages of exemplary embodiments of this application will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings. Several embodiments of this application are illustrated in the drawings by way of example and not limitation, in which:

[0023] In the accompanying drawings, the same or corresponding reference numerals indicate the same or corresponding parts.

[0024] Figure 1 A schematic diagram of a circuit board according to an embodiment of this application is shown;

[0025] Figure 2 A partial schematic diagram of the circuit board assembly structure according to an embodiment of this application is shown;

[0026] Figure 3 A schematic diagram of the composition structure of the lens module and the vehicle lamp according to an embodiment of this application is shown;

[0027] Figure 4 A cross-sectional schematic diagram of the lens module and vehicle headlight according to an embodiment of this application is shown;

[0028] Figure 5 A partial schematic diagram of a circuit board assembly structure according to another embodiment of this application is shown;

[0029] Figure 6 A cross-sectional schematic diagram of a lens module and a vehicle headlight according to another embodiment of this application is shown;

[0030] Figure 7 This illustration shows a schematic diagram of the installation of the arc-shaped memory metal sheet according to an embodiment of this application;

[0031] Figure 8 This illustration shows a schematic diagram of the installation of the arc-shaped memory metal sheet according to an embodiment of this application;

[0032] Figure 9 A schematic diagram of the installation of the rhomboid memory metal sheet according to an embodiment of this application is shown.

[0033] In the diagram: 1. Circuit board; 2. Light source; 3. Reflector bowl; 4. Lens; 5. Heat sink; 6. High beam module; 7. Bracket; 10. Notch; 11. Light blocking part; 12. Upper contour line; 13. Light blocking plate; 14. Shape memory alloy structure; 15. Support arm; 16. Left arm; 17. Right arm; 18. Arc plate; 19. Base plate; 20. Protrusion; 21. Left terminal; 22. Right terminal; 141. Left shape memory metal sheet; 142. Right shape memory metal sheet; 143. Left fixing plate; 144. First metal sheet; 145. Second metal sheet; 146. Arc groove plate; 147. Third metal sheet; 148. Fourth metal sheet; 149. Right fixing plate. Detailed Implementation

[0034] To make the objectives, features, and advantages of this application more apparent and understandable, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0035] Example 1:

[0036] like Figure 1 and Figure 2 As shown, a circuit board 1 has a light source 2 and a reflector 3 fixed above it, so that the circuit board 1 extends obliquely upward along the direction of light irradiation or reflection from the light source 2. A light-blocking part 11 is provided at the front edge of the circuit board 1, and the light-blocking part 11 has an arc-shaped concave notch 10. The center of the light source 2, the center of the reflector 3, and the center of the notch 10 are all in the same vertical plane, and the upper contour line 12 of the notch 10 forms the light cutoff line of the light pattern. Figure 4 As shown, circuit board 1 is tilted at a certain angle relative to the horizontal plane, and the front end of circuit board 1 is higher than the rear end. The front end of circuit board 1 can partially block the light from the light source 2 and the reflector bowl 3. Figure 4 As shown, the arrows indicate the direct direction of light from light source 2 or the direction of light emission after reflection by reflector bowl 3. In the diagram, the light is emitted obliquely forward, and after passing through lens 4, most of the light rays will be emitted obliquely downward.

[0037] like Figure 3 and Figure 4 As shown, a lens module includes the circuit board 1 described above, and also includes a lens 4. Figure 4 The diagram shows a vertical cross-section. The reflector bowl 3 has an elliptical inner profile in the vertical direction. The light source 2 is located at the first focal point of the ellipse. The light emitted from the light source 2 is reflected by the reflector bowl 3 and reaches the notch 10 at the edge of the circuit board 1. The second focal point of the ellipse is located at the center of the notch 10, and the focal point of the lens 4 is also located at the center of the notch 10. This design ensures that the second focal point coincides with the focal point of the lens 4, allowing the lens 4 to convert the converging light into collimated light (parallel light). The edge of the circuit board 1 directly intercepts the converging light at the focal point, forming a sharp cutoff line (such as the light-dark boundary line required by ECE regulations).

[0038] Example 2:

[0039] like Figure 1 , Figure 2 and Figure 4As shown, a lens module includes a circuit board 1, a reflector bowl 3, a light source 2, and a lens 4. The light source 2 and reflector bowl 3 are positioned above the circuit board 1. The circuit board 1 is tilted at a certain angle relative to the horizontal plane, so that it extends upwards along the direction of light illumination or reflection from the light source 2. A light-blocking portion 11 is provided at the front edge of the circuit board 1, and a light-blocking plate 13 is provided on the light-blocking portion 11. The outer contour line of the upper end of the light-blocking plate 13 can block part of the light reaching the lens 4, forming a light-dark cutoff line. The light-blocking plate 13 is an aluminum sheet or a tin sheet, which is fixed to the extension of the circuit board 1 by welding. The circuit board 1 uses FR-4 substrate or a metal substrate. The specific process flow is: circuit board 1 fabrication → pattern etching → electroplating of the light-blocking area → surface passivation treatment. The plating structure is chemical nickel plating, electroplating of matte tin, and welding of aluminum sheets. The light-blocking area and the non-light-blocking area form a sharp cutoff line, which can realize complex gradient light-blocking patterns.

[0040] Example 3:

[0041] like Figure 5 and Figure 6 As shown, in one embodiment, the light-blocking sheet 13 is made of shape memory alloy or fixed to the support arm by a shape memory alloy structure 14, and the support arm is fixed to the circuit board 1.

[0042] like Figure 7 As shown, in one embodiment, the support arm 15 is made of a heat-insulating material or a material with low thermal conductivity, such as polystyrene board or modified polyurethane rigid foam (glass fiber reinforced). The support arm 15 includes a left arm 16 and a right arm 17, which are installed at the same height and have a certain distance between them. The support arm 15 is fixed to the bottom of the circuit board 1 by riveting or welding.

[0043] like Figure 8 As shown, in one embodiment, the shape memory alloy structure 14 is an arc-shaped shape memory metal sheet, which includes a left shape memory metal sheet 141 and a right shape memory metal sheet 142, which are mirror images of each other. The upper ends of the left shape memory metal sheet 141 and the right shape memory metal sheet 142 are electrically connected. The left shape memory metal sheet 141 is provided with a left terminal 21, and the right shape memory metal sheet 142 is provided with a right terminal 22. Applying a certain voltage between the left terminal 21 and the right terminal 22 can heat the left shape memory metal sheet 141 and the right shape memory metal sheet 142.

[0044] like Figure 5 As shown, in one embodiment, the light-blocking plate 13 includes an arc-shaped plate 18 and a base plate 19. The arc surface of the arc-shaped plate 18 faces the light source 2, and the left arm 16 and the right arm 17 are fixed to the lower end of the base plate 19.

[0045] like Figure 9As shown, in one embodiment, the shape memory alloy structure 14 is a rhomboid shape memory metal sheet. The rhomboid shape memory metal sheet includes a left fixing piece 143, a first metal piece 144, a second metal piece 145, an arc-shaped groove piece 146, a third metal piece 147, a fourth metal piece 148, and a right fixing piece 149 connected in sequence. The first metal piece 144 and the second metal piece 145 are directly connected, the third metal piece 147 and the fourth metal piece 148 are directly connected, and the second metal piece 145 and the third metal piece 147 are indirectly connected through the arc-shaped groove piece 146. The included angle between the first metal piece 144 and the second metal piece 145 is equal to the included angle between the third metal piece 147 and the fourth metal piece 148. The left fixing piece 143 and the right fixing piece 149 are disposed in the mounting groove of the support arm 15. The upper end of the arc-shaped groove piece 146 has an arc-shaped groove so that the protrusion 20 at the lower end of the base plate 19 can be inserted into the arc-shaped groove, so that the light-blocking piece 13 can rotate and move relative to the shape memory alloy structure 14.

[0046] In one embodiment, both the left arm 16 and the right arm 17 are provided with the same arc-shaped or rhomboid shape memory metal sheet.

[0047] Example 4:

[0048] like Figure 3 As shown, a vehicle headlight includes the lens module as described in embodiments 1-3, and also includes a heat sink 5. The circuit board 1 is fixed on the heat sink 5, and the heat sink 5 and the lens 4 are fixed on the bracket 7. The headlight also includes a high beam module 6, and the lens 4 module has two lenses located on both sides of the high beam module 6.

[0049] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A circuit board (1) that works in conjunction with a light source (2) and a reflector (3), characterized in that: The circuit board (1) is set at a certain angle relative to the horizontal plane, so that the circuit board (1) extends upward along the direction of light irradiation or reflection of the light source (2). A light-blocking part (11) is set at the front edge of the circuit board (1). The light-blocking part (11) has a concave notch (10). The center of the light source (2), the center of the reflector bowl (3) and the center of the notch (10) are in the same vertical plane. The upper contour line (12) of the notch (10) forms the light and dark cutoff line of the light pattern.

2. A lens module, characterized in that: The circuit board (1) according to claim 1 is included, and a lens (4) is also included. The reflector bowl (3) has an elliptical inner profile in the vertical direction. The light source (2) is located at the first focal point of the ellipse. The light emitted by the light source (2) is reflected by the reflector bowl (3) and reaches the notch (10) at the edge of the circuit board (1). The second focal point of the ellipse is located at the center of the notch (10). The focal point of the lens (4) is also located at the center of the notch (10).

3. A lens module, characterized in that: The circuit board (1) as described in claim 1 is further comprising a reflector bowl (3), a light source (2), and a lens (4). The light source (2) and the reflector bowl (3) are provided above the circuit board (1). The circuit board (1) is tilted at a certain angle relative to the horizontal plane, so that the circuit board (1) extends upward at an angle along the direction of light irradiation or reflection from the light source (2). The light-blocking part (11) is provided at the front edge of the circuit board (1). The light-blocking part (11) is provided with a light-blocking plate (13). The outer contour of the light-blocking plate (13) can block part of the light reaching the lens (4) to form a light cutoff line of the light pattern.

4. The lens module according to claim 3, characterized in that: The light-blocking plate (13) is made of shape memory alloy or fixed to the support arm (15) by a shape memory alloy structure (14), and the support arm (15) is fixed to the circuit board (1).

5. The lens module according to claim 4, characterized in that: The support arm (15) includes a left arm (16) and a right arm (17), which are mounted at the same height and have a certain distance between them.

6. The lens module according to claim 5, characterized in that: The shape memory alloy structure (14) is a rhombus-shaped memory metal sheet, which includes a first metal sheet (144), a second metal sheet (145), a third metal sheet (147), and a fourth metal sheet (148). The first metal sheet (144) is directly connected to the second metal sheet (145), the third metal sheet (147) is directly connected to the fourth metal sheet (148), and the second metal sheet (145) is directly or indirectly connected to the third metal sheet (147). The included angle between the first metal sheet (144) and the second metal sheet (145) is equal to the included angle between the third metal sheet (147) and the fourth metal sheet (148).

7. The lens module according to claim 5, characterized in that: The shape memory alloy structure (14) is an arc-shaped memory metal sheet, which includes a left memory metal sheet (141) and a right memory metal sheet (142). The left memory metal sheet (141) and the right memory metal sheet (142) are mirror-symmetrical.

8. The lens module according to claim 6 or 7, characterized in that: Both the left arm (16) and the right arm (17) are provided with the same arc-shaped memory metal sheet or rhomboid memory metal sheet.

9. The lens module according to claim 8, characterized in that: The light-blocking plate (13) includes an arc plate (18) and a base plate (19). The arc surface of the arc plate (18) faces the light source (2). The left arm (16) and the right arm (17) are fixed to the lower end of the base plate (19).

10. A vehicle light, characterized in that: The lens module as described in claim 9 is further provided with a heat sink (5).

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