An optical component for automobiles based on an integrated lens light guide

Abstract

This utility model relates to the field of automotive parts manufacturing technology, specifically disclosing an automotive optical component based on an integrated lens light guide, including a PCB board, an LED light, and an integrated lens light guide. This utility model features a novel concept and scientific design, with advantages including: high-efficiency light focusing: the silicone lens, through Fresnel or aspherical structure design, precisely couples LED light into the light guide, reducing scattering loss; low interface thermal resistance: the integrated molding process eliminates the air gap between the light guide and the convex lens, and combined with high thermal conductivity silicone material, significantly improves heat dissipation efficiency, ensuring safe and reliable operation; and a reasonable and simplified structure: the integrated design avoids assembly errors of traditional split structures, reducing installation and adjustment complexity and cost.

Description

Technical Field

[0001] This utility model relates to the field of automotive parts manufacturing technology, specifically to an optical component for automobiles based on an integrated lens light guide. Background Technology

[0002] In traditional automotive headlights, LED light is transmitted and diffused through a light guide. However, total internal reflection losses within the light guide and heat generation from the LED lead to reduced luminous efficiency and shortened lifespan. Existing technologies often use silicone lenses at the light-guiding end to adjust beam distribution, but these still suffer from the following problems: 1. Insufficient light-gathering efficiency: Traditional silicone lenses are mostly spherical or simple aspherical designs, which cannot precisely control the propagation path of light in the light guide, resulting in limited light-gathering effect.

[0003] 2. Poor heat dissipation: The interface thermal resistance between the light guide and the lens is high, making it difficult to effectively dissipate the heat generated by the LED, which can easily lead to aging and light decay of the light guide material.

[0004] 3. The structure is not entirely reasonable: The assembly of the split lens and the light guide will introduce interface reflection and tolerance accumulation, which will reduce the stability of optical performance. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of the existing technology by providing an integrated silicone lens and light guide vehicle lamp optical assembly.

[0006] The technical solution adopted in this utility model is as follows: An optical component for automobiles based on an integrated lens light guide includes a PCB board, an LED lamp, and an integrated lens light guide. The integrated lens light guide includes an integrated convex lens, a light guide, and fins. The end face of the convex lens is the light-incident surface, and its convex surface is the light-exit surface. The end face of the convex lens is an aspherical or Fresnel structure, and its convex surface is an aspherical structure. The fins are fixedly connected to the convex surface of the convex lens. The main body of the light guide has a circular cross-section and a light-exit side. The back side of the light-exit side is a reflective side, and the reflective side is provided with light guide teeth. The convex lens, with its convex aspherical structure, is seamlessly connected to the front end of the light guide as a single unit.

[0007] The convex lens of the integrated lens light guide is made of high-refractive-index silicone material with added thermally conductive filler, and the light guide of the integrated lens light guide is made of PMMA or PC material.

[0008] The optical guide teeth have a height of 0.2 mm to 0.3 mm, a front angle of 10 degrees to 40 degrees, and a rear angle of 80 degrees to 85 degrees.

[0009] The LED light is a flip-chip LED or a vertical LED.

[0010] This utility model relates to an integrated lens-light guide optical component for automobiles. It features a novel concept and scientific design, and the integrated lens-light guide optical component has the following advantages: 1. High-efficiency light focusing: The silicone lens, through Fresnel structure or aspherical structure design, accurately couples the LED light into the light guide, reducing scattering loss.

[0011] 2. Low interfacial thermal resistance: The integrated molding process eliminates the air gap between the light guide and the convex lens, and combined with high thermal conductivity silicone material, it significantly improves heat dissipation efficiency and ensures safe and reliable operation.

[0012] 3. Simplified and reasonable structure: The integrated design avoids the assembly errors of traditional split structures, reducing the complexity and cost of installation and adjustment. Attached Figure Description

[0013] The accompanying drawings, which are included to provide a further understanding of the present invention and form part of this invention, illustrate exemplary embodiments and are used to explain the present invention, but do not constitute an undue limitation of the present invention. In the drawings: Figure 1 This is a schematic diagram of the optical component based on the integrated lens and light guide of this utility model; Figure 2 for Figure 1 Diagram showing the view from below; Figure 3 for Figure 2 Schematic diagram of sectional view along direction AA; Figure 4 for Figure 3 Enlarged schematic diagram of part C; Figure 5 for Figure 3 A left-view diagram; Figure 6 for Figure 5 Rear view diagram; Figure 7 for Figure 6 A partial schematic diagram of the BB-direction cross-section; Figure 8 for Figure 7 Enlarged schematic diagram of part D; In the diagram: 1-PCB board; 2-LED lamp; 3-integrated lens light guide; 31-convex lens; 311-convex surface; 312-end face; 32-light guide; 321-light emitting side; 322-reflecting side; 323-light guide teeth; 33-fin; α-front angle; β-rear angle. Detailed Implementation

[0014] To make the objectives, technical solutions, and advantages of this utility model clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described below are only used to explain this utility model. Key terms that need attention in these descriptions, including "integrated lens light guide," "incident surface," "exit surface," "exit side," "back side," "front corner," and "rear corner," are only for the purpose of facilitating a concise and clear description of this utility model and should not be construed as limiting this utility model.

[0015] like Figure 1-3 As shown, this utility model is an optical component based on an integrated lens light guide, including a PCB board 1, an LED lamp 2, and an integrated lens light guide 3. The integrated lens light guide 3 includes an integrated convex lens 31, a light guide 32, and fins 33. The convex lens 31 has the function of converging light, hence it is also called a converging lens, and is used to transmit the light source of the LED lamp 2. Its end face 312 is the light-incident surface, and its convex surface 311 is the light-exit surface. See [reference needed]. Figure 4 As shown, the end face 312 of the convex lens 31 is an aspherical or Fresnel structure, and its convex surface 311 is an aspherical structure, which optimizes the incident angle of light, reduces total internal reflection loss, and improves light transmission performance. To improve heat dissipation performance, the fins 33 are fixedly connected to the convex surface 311 of the convex lens 31, and thermally conductive fillers are added inside the high refractive index (n≥1.5) silicone material used, which is more conducive to heat dissipation. The light guide 32 is made of PMMA or PC material, and its main cross-section is circular. See [reference needed]. Figure 5-6 As shown, its light-emitting side 321 projects light onto the vehicle headlight, and the back side of the light-emitting side 321 is the reflective side 322, see [reference]. Figure 7-8 As shown, the reflective side 322 is provided with light guide teeth 323. The height of the micro-structure light guide teeth 323 is 0.2-0.3 mm, its front angle α is in the range of 10-40 degrees, and its rear angle β is in the range of 80-85 degrees. After the convex lens 31 is first injection molded, it is then multi-color injection molded. Due to the aspherical structure of its convex surface 311, it is seamlessly connected to the front end of the light guide 32 as a whole.

[0016] The LED lamp 2 adopts either a flip-chip LED or a vertical LED.

[0017] I. Flip Chip LED The typical structure, from top to bottom, is as follows: 1. Direct electrical and mechanical connection between the chip and the substrate is achieved through arrayed solder balls or conductive colloid; 2. Sapphire substrate; 3. N-type semiconductor light-emitting layer; 4. P-type semiconductor layer; 5. Bottom surface electrode (including P electrode and N electrode); Flip-chip technology places the electrodes on the bottom of the chip instead of the traditional top. Flip-chip LEDs use a leadless structure. Behind this simple flipping lies a number of advantages. Its working principle achieves high efficiency through the following methods: 1. No pins, enhanced reliability. Flip-chip LEDs eliminate the need for wire bonding, thus completely eliminating defects caused by wire bonding.

[0018] 2. Avoiding obstruction and improving luminous efficiency. Since the electrodes of a standard LED lamp are located at the top, this inevitably causes some obstruction to the light emission. In contrast, the flip-chip design places the electrodes at the bottom, thus eliminating this obstruction problem and improving overall luminous efficiency.

[0019] 3. Direct connection for better heat dissipation. The electrodes of flip-chip LEDs are mostly directly connected to the substrate, so heat is primarily conducted along the substrate direction, resulting in short-path heat dissipation. Compared to conventional LEDs, flip-chip LEDs exhibit better thermal resistance, leading to superior heat dissipation performance.

[0020] II. Vertical Chip Structure LED The most significant characteristic of vertical chip structure LEDs is that the P / N electrodes are located on opposite sides of the LED epitaxial layer, allowing current to flow perpendicularly through the entire chip. Its basic structural features include: 1. Remove the sapphire substrate with poor thermal conductivity; 2. Replace with a substrate with high thermal conductivity (such as Si, Ge, Cu, etc.); 3. The current path is perpendicular to the light-emitting surface, completely solving the "current congestion" problem of horizontal structures; Vertical chip structure LEDs achieve high performance through the following mechanism: 1. Vertical current conduction: The current flows almost entirely vertically through the LED epitaxial layer, with very little lateral flow, thus avoiding localized high temperatures; 2. High-efficiency thermal management: High thermal conductivity substrate replaces sapphire, significantly improving heat dissipation efficiency; 3. Uniform current distribution: With electrodes located on both sides, the current distribution is more uniform and can withstand higher driving currents.

[0021] The present invention relates to a manufacturing method for an optical component based on an integrated lens and light guide, comprising the following process steps: Step A: Injection molding of convex lens 31 A high-refractive-index (n≥1.5) silicone material is used. To facilitate heat dissipation of the convex lens 31, thermally conductive filler graphene or metal nanoparticles are uniformly added inside the silicone material. Using liquid silicone injection molding, the convex lens 31 is formed with an aspherical or Fresnel structure at its end face 312 and an aspherical convex surface 311. The aspherical or Fresnel structure of the end face 312 optimizes the light incident angle and reduces total internal reflection loss. The aspherical structure of the convex surface 311 effectively improves the light transmission performance at the edge of the lens. Fins 33 are connected to the convex surface 311, achieving a thermal conductivity of over 1.5 W / m·K, further reducing thermal resistance.

[0022] Step B: Injection molding of integrated lens and light guide 3 After the convex lens 31 is injection molded in the previous stage, it is then injection molded in multiple colors using PMMA or PC material to form a seamless connection with the front end of the light guide 2. The reflective side 322 of the light guide 2 is provided with light guide teeth 323. The height of the micro-structure light guide teeth 323 is 0.2-0.3 mm, its front angle α is in the range of 10-40 degrees, and its rear angle β is in the range of 80-85 degrees, forming an integrated lens light guide 3. This simplifies the installation steps and avoids the interface reflection and tolerance accumulation that would be introduced by assembling a separate lens and light guide, which would reduce the stability of optical performance.

[0023] Step C: Configure LED light 2 The LED lamp 2 of this utility model uses either a flip-chip LED or a vertical chip LED.

[0024] Considering factors such as the technology and cost of flip-chip LEDs and vertical chip LEDs, this embodiment prioritizes the use of flip-chip LEDs to form a PCB board 1 equipped with LEDs 2.

[0025] Step D: Optical component installation The PCB board 1 equipped with LED lights 2 and the integrated lens light guide 3 are installed and adapted to the vehicle body to form an optical assembly that provides a light source to the vehicle lights. The above description is merely one embodiment of this utility model. For those skilled in the art, various modifications and variations of this utility model are possible, which will not be elaborated here. Any modifications, equivalent substitutions, or improvements made within the spirit and principle of this utility model should be included within the scope of protection claimed by this utility model.

Claims

1. An optical component for automobiles based on an integrated lens light guide, comprising a PCB board (1), an LED lamp (2), and an integrated lens light guide (3), characterized in that, The integrated lens light guide (3) includes an integrated convex lens (31), a light guide (32), and a fin (33). The end face (312) of the convex lens (31) is the light-incident surface, and its convex surface (311) is the light-outceasing surface. The end face (312) of the convex lens (31) is an aspherical or Fresnel structure, and its convex surface (311) is an aspherical structure. The fin (33) is fixedly connected to the convex surface (311) of the convex lens (31). The main body of the light guide (32) has a circular cross-section and is provided with a light-outceasing side (321). The back side of the light-outceasing side (321) is a reflective side (322). The reflective side (322) is provided with light guide teeth (323). The convex lens (31) is seamlessly connected to the front end of the light guide (32) by its aspherical convex surface (311).

2. The automotive optical component based on an integrated lens and light guide according to claim 1, characterized in that, The convex lens (31) of the integrated lens light guide (3) is made of high refractive index silicone material with added thermally conductive filler, and the light guide (32) of the integrated lens light guide (3) is made of PMMA or PC material.

3. The automotive optical component based on an integrated lens and light guide according to claim 1, characterized in that, The optical guide tooth (323) has a height of 0.2 mm to 0.3 mm, a front angle α in the range of 10 degrees to 40 degrees, and a rear angle β in the range of 80 degrees to 85 degrees.

4. The automotive optical component based on an integrated lens and light guide according to claim 1, characterized in that, The LED (2) is a flip-chip LED or a vertical chip LED.

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