Automotive lighting appliance and manufacturing method thereof
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- MARELLI AUTOMOTIVE LIGHTING ITAL SPA
- Filing Date
- 2023-04-21
- Publication Date
- 2026-06-10
Smart Images
Figure 00000000_0000_ABST
Abstract
Description
[Technical Field]
[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority to European Patent Application No. 22169562, filed April 22, 2022, the entire disclosure of which is incorporated herein by reference.
[0002] The present invention relates to an automotive lighting device and a method for manufacturing the same.
[0003] In particular, the present invention relates to an automotive forward lighting device, and / or an automotive rear lighting device, and / or an automotive side lighting device for an automotive vehicle or automobile or similar motor vehicle of the type including a shell, preferably configured to be embeddable inside a compartment provided on the vehicle body, at least one front lens body formed at least in part from a transparent or translucent material and connected to the shell at its mouth, and at least one LED display device as described in detail below. [Background technology]
[0004] It is known that in the latest generation of automotive lighting systems, electronic technology using LED lighting devices is becoming widespread.
[0005] The popularity of electronics technology using LED lighting devices is essentially due to the ability of LED light sources to achieve many different lighting effects, both static and dynamic, and especially due to their versatility and adaptability to perform any lighting function provided in a vehicle.
[0006] A further requirement for automotive lighting devices with the above LED light sources is that they have a light-emitting surface with a complex three-dimensional profile that can emit light of a specific intensity over a large area, and that the light-emitting surface can be significantly customized in terms of the aesthetic shape of the signaling features and display information messages such as letters or pictograms.
[0007] Some solutions currently being adopted to meet the above requirements include the use of OLEDs (Organic Light Emitting Diodes).
[0008] However, such solutions, in addition to not fully satisfying the above requirements, entail particularly high manufacturing costs which have a non-negligible impact on the cost of the overall lighting device. Summary of the Invention [Problem to be solved by the invention]
[0009] SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide an automotive lighting device that satisfies at least the above requirements, and a method for manufacturing such an automotive lighting device. [Means for solving the problem]
[0010] SUMMARY OF THE INVENTION The object of the present invention is to produce a lighting device for an automobile that overcomes the above technical problems.
[0011] According to the invention, a method for the production of a lighting device for a motor vehicle is also further provided by the corresponding appended claims.
[0012] According to the invention, a method for operating a lighting device for a motor vehicle is also provided by the corresponding appended claims.
[0013] Each claim describes a preferred embodiment of the invention and forms an integral part of the invention.
[0014] The present invention will now be described with reference to the accompanying drawings, which illustrate non-limiting examples of the invention. [Brief explanation of the drawings]
[0015] [Figure 1] FIG. 1 illustrates an embodiment of an automobile equipped with a lighting device constructed in accordance with the principles of the present invention. [Figure 2] FIG. 2 is an exploded view of an automotive lighting device constructed in accordance with the principles of the present invention. [Figure 3] FIG. 3 is an exploded view, with various parts omitted for clarity, of an automotive lighting device constructed in accordance with the principles of the present invention. [Figure 4] FIG. 4 is a perspective view, with various parts removed for clarity, of an automotive lighting device constructed in accordance with the principles of the present invention. [Figure 5] FIG. 5 is another perspective view, with various parts removed for clarity, of an automotive lighting device constructed in accordance with the principles of the present invention. [Figure 6] FIG. 6 is an enlarged top view of a mini LED lighting device installed in an automotive lighting system manufactured in accordance with the principles of the present invention. [Figure 7] FIG. 7 is an enlarged bottom view of a mini LED lighting device installed in an automotive lighting system constructed in accordance with the principles of the present invention. [Figure 8] 8 is a plan view of the support circuit board of the Mini LED device shown in FIG. 6. [Figure 9] 9 is an enlarged top view of the mini LED electronic module of the mini LED device shown in FIG. 6. [Figure 10] FIG. 10 is an enlarged bottom view of the mini LED electronic module shown in FIG. 9. [Figure 11] FIG. 11 is an enlarged side view of the mini LED electronic module shown in FIG. 9. [Figure 12] FIG. 12 is a top view of a planar mini LED lighting device fabricated in accordance with one embodiment. [Figure 13]13 is a cross-sectional view of the mini LED lighting device shown in FIG. 12 taken along line XIII-XIII. [Figure 14] 14 is an enlarged cross-sectional view of the mini LED lighting device shown in FIG. 12 taken along line XIII-XIII. [Figure 15] FIG. 15 is a top view of a mini LED lighting device fabricated according to one embodiment. [Figure 16] 16 is a cross-sectional view of the mini LED lighting device shown in FIG. 15 taken along line XVI-XVI. [Figure 17] 17A and B are enlarged cross-sectional views of respective portions of the mini LED lighting device shown in FIG. 16 arranged on a plane. [Figure 18] 18A and B are enlarged cross-sections of respective portions of the mini LED lighting device shown in FIG. 16, with adjacent mini LED light-emitting displays tilted with respect to each other. [Figure 19] FIG. 19 is a top view of a planar mini LED lighting device fabricated according to the third embodiment. [Figure 20] FIG. 20 is a cross-sectional view of the mini LED lighting device shown in FIG. 19 taken along line XX-XX. [Figure 21] 21A and 21B are enlarged cross-sectional views of respective portions of the mini LED lighting device shown in FIG. 20. [Figure 22] 22A and 22B are enlarged cross-sectional views of respective portions of the mini LED lighting device shown in FIG. 19, with adjacent mini LED light-emitting displays tilted with respect to each other. [Figure 23] 23A and 23B are enlarged cross-sectional views of respective portions of a mini LED lighting device fabricated according to the fourth embodiment. [Figure 24] 24A and 24B are enlarged cross-sectional views of respective portions of a mini LED lighting device fabricated according to a fourth embodiment, in which adjacent mini LED light-emitting displays are tilted with respect to each other. [Figure 25]FIG. 25 shows a top view of a trapezoidal shaped mini LED electronic module used in a mini LED lighting device for automotive lighting manufactured according to the present invention. [Figure 26] FIG. 26 shows a bottom view of a trapezoidal shaped mini LED electronic module used in a mini LED lighting device for automotive lighting made in accordance with the present invention. [Figure 27] FIG. 27 shows a top view of a square shaped mini LED electronic module used in a mini LED lighting device implemented in an automotive lighting system manufactured in accordance with the present invention. [Figure 28] FIG. 28 shows a bottom view of a square shaped mini LED electronic module used in a mini LED lighting device implemented in an automotive lighting system made in accordance with the present invention. [Figure 29] FIG. 29 shows a top view of a portion of a possible configuration of a mini LED lighting device having a generally trapezoidal shape. [Figure 30] FIG. 30 shows one circuit connection scheme of a driver in a mini LED lighting device adapted to be implemented in an automotive lighting system manufactured according to the present invention. [Figure 31] FIG. 31 shows another circuit connection scheme of a driver in a mini LED lighting device adapted to be implemented in an automotive lighting system manufactured according to the present invention. [Figure 32] FIG. 32 shows an example of an optical information communication function performed by an automotive lighting device manufactured according to the present invention. [Figure 33] FIG. 33 shows another example of an optical information communication function performed by an automotive lighting device manufactured in accordance with the present invention. [Figure 34] FIG. 34 shows yet another example of an optical information communication function performed by an automotive lighting device manufactured in accordance with the present invention. DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention will now be described in detail with reference to the accompanying drawings to enable those skilled in the art to make and use the present invention.
[0017] Various modifications to the described embodiments will be readily apparent to those skilled in the art, and the general principles described may be applied to other embodiments and applications of the invention without departing from the scope of protection of the invention.
[0018] Therefore, the present invention should not be considered limited to the embodiments described and illustrated, but should be accorded the widest scope of protection consistent with the principles and features described and claimed herein.
[0019] 1, reference numeral 1 generally generally indicates an automotive lighting device (also referred to as an automotive headlight or light assembly) disposed on one side of a vehicle 100. The vehicle 100 may be, by way of example, a car, a truck, a large bus, or any similar motor vehicle. The vehicle 100 includes an electronic control unit 200 electronically connected to the automotive lighting device 1 for controlling the automotive lighting device 1 to perform the vehicle's lighting functions.
[0020] The automotive lighting device 1 is (rigidly) coupled to and / or integrated into the vehicle 100 at the front and / or the side and / or the rear. In the embodiment shown in Figure 1, the automotive lighting device 1 corresponds to the automotive rear lighting device of the vehicle 100.
[0021] A person skilled in the art will in any event understand that the present invention is not limited to automotive rear lighting systems and that the present invention can be applied in a generally similar manner to any automotive lighting system, for example to the front and / or side and / or rear lighting systems of a motor vehicle.
[0022] The automotive lighting device 1 is configured to perform one or more pre-configured automotive lighting functions, including light-based information and communication functions that convey information by the presentation of numerous types of luminous images / symbols, as well as light-based signaling and / or lighting functions, i.e. (traditional) light photometric functions.
[0023] As shown in Figures 32-34, when the automotive lighting device 1 performs a photometric function (e.g., sidelights, stoplights, turn signals, etc.), the automotive lighting device 1 displays or generates an image. The image may include, for example, a predefined shape, pictogram, and / or symbol (see Figures 32-34). The image generated by the automotive lighting device 1 may be static (fixed) and / or dynamic (moving image and / or image that moves along the light-emitting surface of the lighting device).
[0024] The photometry-related functions described above may, for example, include lighting functions (such as dipped beams, main beams, and fog lights) to illuminate the area around the vehicle 100 so that the driver can see the roadway. Additionally or alternatively, the photometry-related functions may include signaling functions to indicate the presence of the vehicle 100. Additionally or alternatively, the photometry-related functions may include functions to indicate the location of the vehicle 100. Additionally or alternatively, the photometry-related functions may include signaling functions to indicate a turn (turn signal) for the vehicle 100, and / or a braking (stop) condition, and / or a reverse gear condition, and / or an alarm / emergency condition, and / or a vehicle lock / unlock condition, and / or similar automotive conditions.
[0025] Additionally or alternatively, when the automotive lighting device 1 performs an optical communication function, the automotive lighting device 1 may display or generate text messages, pictograms, and / or symbols, which may be static (fixed) and / or dynamic (animated or moving along the light-emitting surface of the lighting device).
[0026] In other words, in the following description, the term automotive lighting device 1 should be understood to be selected from at least a forward lighting device, a rear lighting device, a side lighting device, an exterior width light, a direction indicator light (commonly called a turn signal), a stop light (commonly called a stop light), a fog light, a reverse gear light, a dipped beam light, a main beam light, a lighting device located on the front grille, or any other type of lighting device mounted on the vehicle 100.
[0027] 2 to 5, the automotive lighting device 1 may include a shell 2, for example a rear shell. In the illustrated example, the shell 2 is cup-shaped to have an internal cavity, which is preferred but not required. The rear shell 2 may be configured to be mounted, for example, inside the body of the vehicle 100 (see FIG. 1), or inside a compartment (not shown) provided on the body, which is preferred but not required.
[0028] 2, the automotive lighting device 1 may further include at least one lens body 3, for example, a front lens body. The lens body 3 may be formed, for example, from an at least partially transparent or translucent material. The lens body 3 may be configured, for example, to be coupled to the shell 2 at the opening of the shell 2 so as to close the opening.
[0029] As shown in FIGS. 2 and 3, the automotive lighting device 1 may further comprise an inner wall 4.
[0030] According to a possible embodiment, the inner wall 4 may conveniently be formed with a pre-set three-dimensional shape, which according to the convenient embodiment shown in Figures 1 to 5 may have at least one curved surface, a curved section (for example, partially concave or convex).
[0031] Those skilled in the art will understand that the present invention is not limited to three-dimensional shapes corresponding to curved surfaces or curved sections, but may also provide other three-dimensional shapes, for example polyhedral shapes. Furthermore, those skilled in the art will understand that the three-dimensional shape of wall 4 may have a so-called mixed or irregular geometry, i.e. may be formed by a geometric combination of one or more curved surfaces and / or one or more polyhedral surfaces.
[0032] According to the exemplary embodiment shown in Figures 2 to 4, the automotive lighting device 1 may comprise a support frame 5 housed within the shell 2. In the example shown in Figures 2 to 4, the support frame 5 has a quasi-planar three-dimensional shape. According to such an embodiment, the inner wall 4 consists of a three-dimensional surface or wall of the support frame 5.
[0033] Those skilled in the art will appreciate that according to an alternative (not shown) variant of the embodiment, for example one in which the support frame 5 is absent, the three-dimensional wall 4 can be formed / obtained directly in or on the shell 2, i.e. the three-dimensional wall 4 can consist of a surface or face or an inner wall of the shell 2. Conveniently, the inner wall 4 can be oriented towards the opening of the shell 2, for example facing the lens 3.
[0034] According to the invention, the automotive lighting device 1 comprises a mini LED lighting device 6 .
[0035] According to the embodiment shown in Fig. 3, the mini LED lighting device 6 may be coupled to the interior wall 4 by a fixing device 4b. The fixing device 4b may comprise a screw 4b and / or any similar equivalent device. By way of example, according to an embodiment not shown, the fixing device 4b may comprise a spacer element or a similar member with an adjustment screw for adjusting the position / distance of the fixing point of the mini LED lighting device 6 relative to (from) the wall 4.
[0036] 6, the mini LED lighting device 6 has a first surface on which the mini LEDs 6a are located, the mini LEDs 6a being arranged on the first surface to form a light emitting surface 8 of the automotive lighting apparatus 1 adapted to emit light.
[0037] 2, 3 and 4, the light emitting surface 8 of a mini LED lighting device 6 formed from (consisting of) mini LEDs 6a is conveniently uniform and continuous across the area occupied by the mini LEDs 6a - in other words, the mini LEDs 6a have a constant pitch across the area.
[0038] 6 and 7, the mini LED lighting device 6 further has a second surface opposite the first surface and positioned at least partially seated on the inner wall 4 or a portion thereof.
[0039] According to a possible embodiment shown in Figures 2 and 5, the automotive lighting device 1 may preferably, but not necessarily, comprise a mask frame 7. The mask frame 7 may be plate-shaped or have a three-dimensional shape, and is configured to be coupled to the support frame 5 and / or the shell 2 so as to be at least partially positioned above the first side of the mini LED lighting device 6.
[0040] 2 and 5, the mask frame 7 comprises a rectangular bezel that extends at least partially over the outer edge portion of the first face (without the mini LEDs 6a) of the mini LED lighting device 6 to confine and maintain the mini LED lighting device 6 in abutting position against the underlying support frame 5. The mask frame 7 is conveniently formed with a central opening that leaves the light emitting surface 8 of the mini LED lighting device 6, i.e. the surface occupied by the mini LEDs 6a, uncovered.
[0041] According to the present invention, the mini LED lighting device 6 does not include a liquid crystal panel facing the mini LEDs 6a (there is no liquid crystal panel facing the mini LEDs 6a). In other words, in use, the light emitted by the mini LEDs 6a of the mini LED lighting device 6 passes directly through the lens body 3 without the intervention of a liquid crystal panel.
[0042] 6 to 11, the mini LED lighting device 6 conveniently has a modular architecture (is made up of modules). The mini LED lighting device 6 comprises at least one supporting circuit board 10 and a plurality of mini LED electronic modules 11.
[0043] As shown in Figures 6-8, 12, and 15, support circuit board 10 includes one support portion 25. Support circuit board 10 has a plate-like polygonal shape, e.g., a quasi-rectangular shape, and is made of a rigid material (which does not bend easily). Support circuit board 10 has a surface 10a (shown in Figures 6 and 8), a surface 10b (shown in Figure 7) opposite surface 10a, and an outer (edge) side or end 10c.
[0044] 9 to 11, the mini LED electronic modules 11 have a flat plate shape and are adjacent to each other and also adjacent to and coupled to the support portion 25 of the support circuit board 10.
[0045] The mini LED electronic modules 11 conveniently have a polygonal shape and are rigidly fixed to the surface 10a of the supporting circuit board 10 such that their outer surfaces 11a abut against the outer surfaces 11a of one or more adjacent mini LED electronic modules 11.
[0046] In the accompanying drawings and the following disclosure, explicit reference is made to a simplified embodiment of a mini LED lighting device 6 in order to clearly explain the invention without loss of generality. The embodiment comprises two side-by-side rows or lines of mini LED electronic modules 11 (corresponding to the side-by-side arrangement in Figures 4, 5, 6, 12 and 15), each row comprising five mini LED electronic modules 11 each extending parallel to axis A and aligned with corresponding mini LED electronic modules 11 in the other row (totalling ten mini LED electronic modules 11).
[0047] In the example shown in Figures 1 to 24B, the mini LED electronic modules 11 have the same rectangular shape and dimensions and are arranged side by side on the surface 10a of the supporting circuit board 10, with their sides 11a abutting each other.
[0048] In the examples shown in FIGS. 9, 10, and 11, each of the mini LED electronic modules 11 includes a circuit base 12, a mini LED array 13, and an LED driver 14.
[0049] The circuit base 12 comprises a pressed electronic substrate having a flat shape corresponding to the flat shape of the mini LED electronic module 11. The circuit base 12 is preferably made of a rigid material, i.e. a material that does not bend / flex (easily), which may comprise, for example, vetronite or glass fiber or the like, and which has a defined thickness and which carries electrical tracks (not shown).
[0050] The circuit base 12 has a surface 12a (first surface), a surface 12b (second surface) opposite to the surface 12a, and a series of outer surfaces 12c.
[0051] The mini LED array 13 is firmly bonded to the surface 12a of the circuit base 12. The mini LED array 13 includes (is formed from) a plurality of mini LEDs 6a electrically connected to electrical tracks of the circuit base 12. The mini LEDs 6a are arranged to cover the entire surface 12a. The mini LEDs 6a of the mini LED array 13 are conveniently arranged on the surface 12a to form columns and rows. In the illustrated example, the mini LED array 13 consists of a matrix of mini LEDs 6a formed by rows and columns of mini LEDs 6a aligned with one another.
[0052] Each mini LED 6a has a preset pitch with respect to its immediate neighboring mini LEDs 6a. The pitch refers to the center-to-center distance between two adjacent mini LEDs 6a. According to the present invention, the preset pitch may, for example, be comprised of a distance between about 0.3 mm and about 2 mm.
[0053] As shown in Figure 10, the LED driver 14 is coupled to the surface 12b of the circuit base 12. Preferably, the LED driver 14 comprises a microprocessor electronic module. The LED driver 14 is conveniently located in the center of the surface 12b. The LED driver 14 may be electrically connected to the mini LEDs 6a of the mini LED array 13 by electrical tracks on the circuit base 12. The LED driver 14 is configured to selectively control each mini LED 6a of the mini LED array 13.
[0054] According to a convenient embodiment, the mini LEDs 6a and the LED driver 14 are SMD (surface mounted devices) electronic components, electrically and mechanically coupled to the surface 12a by an SMT (surface mounting) process. The mini LEDs 6a may have dimensions of about 100 μm to about 1 mm.
[0055] Applicant has discovered that for the manufacture of the mini LED lighting devices 6 that are the object of the present invention, the architecture of the mini LEDs (which are SMD) and the LED drivers which are SMD is advantageous because it allows for the use of conventional pick-and-place factories / machines to manufacture a wide range of mini LED lighting devices 6 with different dimensional and / or shape features, reducing manufacturing costs.
[0056] In any case, those skilled in the art will understand that the present invention is not limited to the mini LEDs 6a (which are SMD), but that the mini LEDs 6a may also be chip components and may be electrically and mechanically coupled to the surface 12a by a COB (chip on board) mounting process.
[0057] Furthermore, by using the above mini LED electronic modules 11 having an electronic module architecture for using LED drivers 14 directly implemented on the mini LED electronic modules 11, it becomes possible to effectively and precisely implement coordinated control of each mini LED electronic module 11 through a standardized and simplified activation process, since the above process is configured for an electronic architecture that complies with the same standards as the mini LED electronic modules 11 that are assembled to produce the mini LED lighting device 6.
[0058] According to the embodiment shown in FIGS. 6 and 12 to 14, the surface 12b of the circuit base 12 of the mini LED electronic module 11 is firmly fixed to the surface 10a of the supporting circuit board 10.
[0059] According to the embodiment shown in Figures 12 to 14, the circuit bases 12 of the mini LED electronic modules 11 are arranged adjacent to each other on the face 10a of the supporting circuit board 10, such that the mini LED arrays 13 are arranged side by side to form the light emitting surface 8.
[0060] In the example shown in Figures 12 to 14, the circuit base 12 is arranged on the support circuit board 10 so that the side surfaces 12c are aligned with each other. In the example shown in Figures 12 to 14, the support circuit board 10 is formed by a single (united) support portion 25, i.e., it is made up of a group of distinct and separated support portions 25. In the example shown in Figures 12 to 14, when the support circuit board 10 is coupled / fixed to the wall 4, the support circuit board 10 may conveniently be configured with a reduced thickness so as to be at least partially folded. The Applicant has found that this solution is advantageous for walls 8 having a surface with a small curvature. In such a case, the technical effect is achieved of being able to produce a continuous light-emitting surface 8 (with uniform luminous intensity) that follows the curved profile of the wall 8 while maintaining a constant pitch between the mini-LEDs 6a.
[0061] With reference to the embodiment shown in accompanying drawings 15, 16 and 17A to 24B, the mini LED electronic module 11 and supporting circuit board 10 are configured to form an articulated structure consisting of a plurality of flat light-emitting mini LED displays 9 (with reference to the embodiment shown in Figures 12 to 14).
[0062] 15, 16 and 17A-24B, the support circuit board 10 comprises a plurality of support portions 25 that support a plurality of mini LED electronic modules 11. The support portions 25 and the corresponding mini LED electronic modules 11 form a light-emitting mini LED display 9. In the accompanying drawings, the light-emitting mini LED display 9 is represented using dashed lines.
[0063] The flat light-emitting mini LED displays 9 have a polygonal shape and are side by side, lying on respective lying planes inclined relative to each other and fixed on the wall 4 side by side.
[0064] Applicant has discovered that in this way the light emitting mini LED display 9 can be arranged on an inclined surface to form a light emitting surface 8 having a three-dimensional shape according to the curvature profile of the lighting device 1, e.g. a curved shape.
[0065] 15 to 22B, the light-emitting mini LED displays 9 are connected to one another to define an articulated structure for each light-emitting mini LED display 9 to lie on an inclined plane relative to the lying surfaces of the other light-emitting mini LED displays 9. An articulated structure in this context refers to an articulated structure that allows each light-emitting mini LED display 9 to undergo at least partial rotational movement relative to the light-emitting mini LED displays 9 about a common linear folding line LP. The light-emitting mini LED displays 9 are free to rotate relative to one another such that the light-emitting surfaces 8 are positioned on their respective inclined lying surfaces to assume a preset three-dimensional shape associated with (corresponding to) the three-dimensional shape of the wall 4 to which the light-emitting mini LED displays 9 are fixed.
[0066] 17A to 22B, the folding line LP is substantially coincident with a side surface 9a of the emissive mini LED display 9. Preferably, the side surface 9a of the emissive mini LED display 9 is substantially coincident with a side surface 11a of the mini LED electronic module 11 adjacent to the side surface 9a.
[0067] According to a possible embodiment shown in Figures 15 to 22B, the mini LED lighting device 6 is configured with grooves 18 formed on the support substrate 10 (e.g. obtained by reducing the thickness) along a direction parallel to and substantially coincident with the folding line LP.
[0068] According to a convenient embodiment shown in Figures 15 to 22B, each groove 18 is obtained on the face 10b of the support circuit board 10 and, together with adjacent grooves 18, defines a support portion 25 of the light-emitting mini LED display 9.
[0069] Each groove 18 is provided on the surface 10 b of the supporting circuit substrate 10 between two adjacent light-emitting mini LED displays 9 .
[0070] The technical effect of the grooves 18 is therefore to allow the support portions 25 of the mini LED lighting device 6 and the corresponding adjacent light-emitting mini LED displays 9 to undergo some angular rotational movement relative to each other about the folding line LP so that they are arranged on a lying surface that is inclined with respect to the lying surface of the adjacent light-emitting mini LED displays 9. In this way, the mini LED lighting device 6 has an articulated structure that allows the light-emitting surface 8 of the mini LED lighting device 6 to be shaped according to a pre-set three-dimensional shape.
[0071] In the exemplary embodiment shown in Figures 17A to 22B, a plurality of rectangular grooves 18 are provided on the surface 10b of the supporting circuit board 10, which are parallel to and spaced apart from each other and extend along a direction perpendicular to the axis A.
[0072] 17A-22B, the grooves 18 extend between the opposite sides 10c of the support circuit board 10 to form support portions 25 of adjacent light-emitting mini LED displays 9. The support portions 25 each have a rectangular shape and contain a group of mini LED electronic modules 11.
[0073] In the exemplary embodiment shown in Figures 15 to 22B, each of the light-emitting mini LED displays 9 includes two mini LED electronic modules 11 sandwiched between each other in a row.
[0074] 17A and 17B show the mini LED lighting device 6 in a first geometric condition in which the support portions 25 of the support circuit board 10 are arranged to sit on planes that are coplanar with one another.
[0075] 18A and 18B show the mini LED lighting device 6 of Figures 17A and 17B in a second geometric condition where the support portion 25 of the support circuit board 10 is positioned on an inclined plane such that the mini LED lighting device 6 and light emitting surface 8 have a three-dimensional structure (with a slightly curved profile). In the second geometric condition shown in Figures 18A and 18B, the light emitting mini LED displays 9 are slightly rotated about the fold line LP such that they are positioned on respective planes that are inclined with respect to each other (along axis A).
[0076] 15-22B, the grooves 18 are formed in the support circuit board 10 to have a depth that is shallower than the thickness of the support circuit board 10. In this embodiment, the support portion 25 of the luminous mini LED display 9 remains connected and not separated by a connecting end of the support circuit board 10 that extends along the fold line LP. The connecting end has a reduced thickness that is configured to bend to allow the luminous mini LED display 9 to rotate about the fold line LP.
[0077] According to the embodiment shown in Figures 15 to 18B, the groove 18 may have a generally U-shaped section that crosses the fold line LP.
[0078] The U-shaped sections of the grooves 18 are conveniently obtained by locally reducing the width of the supporting circuit board 10. The reduction in width is carried out by cutting away material obtained by operating a grinder along a linear direction corresponding to the fold line LP.
[0079] It will be appreciated that in the embodiment shown in Figures 15 to 18B, the supporting circuit board 10 remains in one piece without being divided, since the connecting ends are maintained. This solution is advantageous, on the one hand, because it allows the mini LED lighting device 6 to be quickly mounted in a single operation, and, on the other hand, because it allows the light-emitting surface 8 to have any three-dimensional structure.
[0080] 19 to 22B, the grooves 18 may have V-shaped sections in their transverse direction. Each groove 18 is internally bounded by two opposing flat inner walls 18a. Preferably, the grooves 18 are obtained by V-scoring.
[0081] The angle between the two walls 18a of the groove 18 may be set based on the bending / folding, i.e., maximum rotation, that the emissive mini LED display 9 can achieve with respect to the adjacent emissive mini LED display 9. The technical effect of the V-scoring is to pre-form sloping ends of the support portion 25 that achieve a pre-set mutual tilt between the adjacent emissive mini LED displays 9 when the emissive mini LED displays 9 are seated against each other.
[0082] With reference to the different embodiment shown in Figures 23A and 24B, the support portions 25 of the light-emitting mini LED displays 9 are not maintained connected to each other through the connecting ends of the support circuit board 10 (as was provided in the embodiment shown in Figures 15 to 22B).
[0083] As shown in FIGS. 23A to 24B, the support circuit board 10 is formed by supporting portions 25 of a plurality of distinct and separate light-emitting mini LED displays 9.
[0084] According to this embodiment, adjacent light-emitting mini LED displays 9 lie on respective planes inclined with respect to each other at a preset angle. The light-emitting mini LED displays 9 have flat walls 9b resting on each other on their outer surfaces 9a that abut (seat) each other. The flat walls 9b are inclined with respect to the resting plane of the corresponding light-emitting mini LED display 9 at a corresponding angle.
[0085] Referring to the embodiment shown in FIGS. 23A to 24B, the support portion 25 of the light-emitting mini LED display 9 may be kept connected by a soft connecting strap 35.
[0086] 24A and 24B, at least one side 9a of the light-emitting mini LED display 9 is in contact with the side 9a of an adjacent light-emitting mini LED display 9. The side 9a has a distance corresponding to half the preset pitch with respect to the group of mini LEDs 6a located on the periphery and adjacent to the side 9a.
[0087] As shown in Figures 23A to 24B, the outer contacting sides 25a of the support portions 25 of adjacent light-emitting mini LED displays 9 have flat sidewalls 25b. The flat sidewalls 25b of the support portions 25 of the sides 9a of the light-emitting mini LED displays 9 are inclined at a preset angle with respect to the lying plane of the corresponding support portion 25. The preset angle of the flat sidewalls 25b of the light-emitting mini LED displays 9 is conveniently less than 90 degrees. Light-emitting mini LED displays 9 having corresponding flat sidewalls 25b reciprocally seated relative to each other can lie on respective planes inclined at an angle of 90 degrees or less with respect to each other.
[0088] The outer surface 12c of the base 12 of the mini LED module 11, which is arranged on the support portion 25 and is parallel to and adjacent to the contact side 9a of the light-emitting mini LED display 9, has flat side walls 12d inclined at a preset angle α with respect to the corresponding lying surface of the base 12.
[0089] The sidewall 12d of the circuit base 12 and the sidewall 25b of the corresponding support portion 25 together form the flat sidewall 9b of the contact side 9a of the light-emitting mini LED display 9. The sidewall 12d of the circuit base 12 and the sidewall 25b of the corresponding support portion 25 together form the flat sidewall 9b of the contact side 9a of the light-emitting mini LED display 9 and are coplanar with each other. In other words, the sidewall 9b of the contact side 9a of the light-emitting mini LED display 9 forms a sloping slope, i.e., a sloping flat corner adapted to be seated on the sloping slope or corner of an adjacent light-emitting mini LED display 9.
[0090] 23A-24B, the sloping flat sidewalls 9b of the light-emitting mini LED displays 9 of the mini LED lighting device 6 are positioned to approximately rest against the sloping flat sidewalls 9b of the contacting sides 9a of adjacent light-emitting mini LED displays 9. The light-emitting mini LED displays 9 with corresponding flat sidewalls 9b resting against each other lie on respective planes that are inclined with respect to each other at an angle of 90 degrees or less.
[0091] Preferably, the sloping sidewalls 9b of each light-emitting mini LED display 9 are parallel to the rows of peripheral mini LEDs 6a adjacent to the side 12c of the base 12 along which the walls 9b extend. Preferably, the distance between the rows of peripheral mini LEDs 6a adjacent to the side 12c corresponds approximately to half the preset pitch.
[0092] The Applicant has discovered that by forming the inclination angle of the walls 9b according to the shape that the mini LED lighting device 6 should have and arranging the luminous mini LED displays 9 side by side with the walls 9b abutting / touching each other, it is possible to create a mini LED lighting device 6 whose light emitting surface 8 has a three-dimensional shape but is advantageously continuous, for example, a complex three-dimensional shape, such as a curved or polygonal shape. In particular, the inclined walls 9b of the side surfaces 9a of the luminous mini LED displays 9 keep the side surfaces 12c of the bases 12 in contact with each other when the inclined walls 9b are seated against each other, and prevent a distance from being created between the peripheral rows of adjacent mini LED modules 11 when the adjacent mini LED modules 11 are lying on an inclined plane. This also has the technical effect of maintaining a predetermined pitch between the rows of peripheral mini LED modules 11 belonging to adjacent luminous mini LED displays 9. This makes it possible to obtain a mini LED lighting device 6 having a three-dimensional shape, i.e., a light emitting surface 8 of large dimensions formed according to the three-dimensional profile (e.g., curved) of the inner walls 4. Here, the light emitting surface 8 can emit uniform and continuous light over the entire area without breaking the continuity of the pitch and therefore the continuity of the image between adjacent mini LED modules 11 that are tilted with respect to each other.
[0093] 23A and 23B, it can be seen that the three-dimensional shape of the light-emitting surface 8 of the modular lighting device 6 is obtained when the light-emitting mini LED display 9 is coupled to a wall 8. In this example, the three-dimensional shape of the light-emitting surface 8 is adapted to (according to) the three-dimensional shape of the wall 8 to which the light-emitting mini LED display 9 is coupled.
[0094] However, it is convenient to form the three-dimensional shape of the light emitting surface 8 so that it is not related to the shape of the wall 8. For example, using spacer elements and / or connecting devices (screws with various lengths), it is possible to adjust the tilt of the light emitting mini LED displays 9 in order to obtain a light emitting surface 8 having a three-dimensional shape that is independent of (different from) the three-dimensional shape of the wall 8. In other words, the light emitting surface 8 obtained by bringing the light emitting mini LED displays 9 close together can be formed according to a three-dimensional shape that is different from the three-dimensional shape of the wall 4.
[0095] Referring to the exemplary embodiment shown in FIGS. 9, 10, and 11, the mini LED electronic module 11 and its circuit base 12 have a rectangular shape.
[0096] On the surface 12b of the circuit base 12 are a plurality of pads 20 or electric welding pads formed from a conductive material.
[0097] The pads 20 are adapted to receive (in use) electrical control and / or power signals and are electrically connected to the LED driver 14 and / or mini LED array 13.
[0098] Conveniently, the pads 20 of the mini LED electronic modules 11 are arranged in rows alongside one another along the side 12c of the base 12, adjacent to respective pads 20 arranged along the side adjacent the base 12 of adjacent mini LED modules 6.
[0099] Conveniently, groups of pads 20 present on side 12c and associated with corresponding functions may be replicated on more sides, preferably on all four sides, of circuit base 12. This allows greater freedom in wiring / connecting mini LED electronic modules 11 to one another, resulting in a higher degree of modularity.
[0100] Furthermore, on the surface 12b of the circuit base 12 of the mini LED electronic module 11 there are mechanical pads adapted to firmly fix the base 12 onto the corresponding mechanical connection pads 21 of the support substrate 10, for example during an SMT mounting process.
[0101] Referring to FIG. 9, on the surface 10a of the support substrate 10 there are a number of pads 22 or electrical welding pads arranged to overlap with each of the pads 20 present on the circuit base 12 of the mini LED electronic module 11, thus enabling electrical connection.
[0102] The pads 22 present on the circuit support substrate 10 and associated with adjacent mini LED electronic modules 11 are electrically connected to one another in accordance with a pre-established electrical interconnection, for example, a reflow soldering process.
[0103] Conveniently, each of the pads 22 present on the circuit support substrate 10 and associated with a mini LED electronic module 11 is adjacent to a corresponding pad 22 present on the support substrate 10 and associated with an adjacent mini LED module 11. Conveniently, each of the pads 22 present on the circuit support substrate 10 and associated with a mini LED electronic module 11 is adjacent to a corresponding pad 22 present on the support substrate 10 and associated with an adjacent mini LED electronic module 11.
[0104] The support substrate 10 may include at least one electrical connector 23 adapted to receive control and power signals in use.
[0105] The electrical connectors 23 are conveniently located on one side of the support substrate 10 and are electrically connected to the pads 22 to form electrical connection circuits thereto.
[0106] For example, it may be convenient to form an electrical connection circuit configured in accordance with that provided by a daisy-chain circuit architecture. Figure 30 shows a possible electrical connection circuit with a daisy-chain circuit architecture. In Figure 30, power supply signals are represented by VCC and GND, control signals include a clock signal CLK, and signals corresponding to a bright image are represented by SIN and SOUT.
[0107] The technical effect of this electrical connection circuit is that it implements a serial communication protocol that reduces the number of connections between the LED drivers and allows for a single communication channel for data between the LED drivers 14. Furthermore, the above communication protocol reduces the number of messages sent by the control unit 200 of the vehicle 100 to create an image in the mini LED lighting device 6 because the messages are sent sequentially between the LED drivers.
[0108] In any event, those skilled in the art will appreciate that the present invention is not limited to daisy chain electrical connection circuits, but may also follow circuit architectures different from daisy chain, for example a two-wire I2C serial architecture, as shown in FIG. 30.
[0109] 8 and 9, cooling through holes 26 are formed on the circuit support substrate 10. In the illustrated example, the cooling through holes 26, which are preferably square (rectangular), are formed on the circuit support substrate 10 to accommodate the LED driver 14 of the mini LED electronic module 11 when the circuit base 12 is fixed to the surface 10a of the support circuit substrate 10. The technical effect obtained by the cooling holes 26 is to ensure heat dissipation of the LED driver 14.
[0110] On the surface 12b of the circuit base 12, inside the through-hole 26, further additional electronic elements 27 may be arranged, electrically connected to the LED driver 14 and / or the mini LED array 11.
[0111] Those skilled in the art will appreciate that the present invention should not be considered limited to the embodiments shown in FIGS. 1 to 24B, and that the number and / or size and / or shape and / or arrangement of the Mini LED electronic modules 11 on the supporting circuit board 10 are features that can be modified / varied depending on the size and / or shape of the Mini LED lighting device 6 to be manufactured based on the teachings of the present invention.
[0112] Furthermore, according to the present invention, the polygonal shape of the mini LED electronic module 11 is not limited to a rectangular shape, and the mini LED electronic module 11 may have other polygonal shapes in addition to or alternatively to those described and illustrated above. As shown in the exemplary embodiment shown in Figures 25 to 29, the polygonal shape of the mini LED electronic module 11 may be, by way of example, a triangle, a trapezoid (see Figures 25 and 26), a square (see Figures 27 and 28), a pentagon, a hexagon, an octagon, or the like, among others.
[0113] Those skilled in the art will further appreciate that, in accordance with the present invention, a mini LED lighting device 6 may comprise an assemblage of mini LED electronic modules 11 all having the same shape and dimensions. It will further be appreciated that, in accordance with the present invention, a mini LED lighting device 6 may comprise an assemblage of mini LED electronic modules 11 having different shapes and / or dimensions relative to one another.
[0114] Those skilled in the art will further understand that the mini LED electronics module 11 does not comprise micro LEDs. It will also be understood that the mini LED electronics module 11 does not include micro LEDs consisting of chips / pixels with dimensions less than 100 square micrometers. The mini LED electronics module 11 does not have a micro LED electronic architecture.
[0115] Those skilled in the art will further understand that the size, depth, number, location and orientation of the grooves 18 on the support substrate 10 can be set and changed based on the location and orientation of the fold lines LP to be formed on the mini LED lighting device 6. Furthermore, the fold lines LP can be set and changed based on the three-dimensional shape that the mini LED lighting device 6 is to take.
[0116] Those skilled in the art will further appreciate that the present invention is not limited to grooves 18 having V- or U-shaped sections, but may be provided with other shapes different from V or U shapes.
[0117] 12 to 14, in which the supporting circuit board 10 is a single piece having a flat plate shape without grooves 18 and on which the mini LED electronic module 11 is placed. This embodiment may be suitable for automotive lighting devices with a (flat) planar shape and / or a slightly curved three-dimensional shape.
[0118] In the following, a convenient method for manufacturing the automotive lighting device 1 will be described in accordance with what has been disclosed above.
[0119] The method includes the steps of providing at least one plate-shaped support substrate 10, providing a plurality of planar mini LED electronic modules 11, firmly bonding the planar mini LED electronic modules 11 side by side on the support substrate 10 to form a mini LED lighting device 6, and bonding the support circuit board 10 of the mini LED lighting device 6 to the inner wall 4.
[0120] The method includes the steps of firmly fixing the flat mini LED electronic modules 11 side by side to the support substrate 10 by an SMT surface mounting process based on surface mount technology.
[0121] Prior to firmly bonding the planar mini LED electronic module 11 to the support substrate 10, cooling through holes 26 must be formed on the support circuit board 10 at positions associated with the positions where the LED drivers 14 of the mini LED electronic module 11 will be housed.
[0122] If the support circuit board 10 has grooves 18 and / or consists of a plurality of support portions 25, the step of bonding the support circuit board 10 of the mini LED lighting device 6 to the inner wall 4 comprises fixing the support portions 25 to the inner wall 4 side by side so that they lie on respective lying surfaces that are inclined relative to each other at a preset angle that depends on (varying based on) the three-dimensional shape that the light-emitting surface 8 takes.
[0123] According to the embodiment shown in Figures 23 and 24, in which the support circuit board 10 comprises a plurality of support portions 25, the method comprises the step of arranging adjacent light-emitting mini LED displays 9 so that the inclined flat walls 9b of the outer faces 9a of the corresponding light-emitting mini LED displays 9 rest relative to each other on planes that are inclined relative to each other at an angle according to the three-dimensional shape of the light-emitting surfaces 8.
[0124] According to the embodiment shown in Figures 15 to 22, in which the support circuit board 10 comprises grooves 18 defining the support portions 25, the method comprises at least partially rotating the light-emitting mini LED displays 9 relative to one another about the fold lines LP so as to position the light-emitting mini LED displays 9 on their respective inclined planes while the outer surfaces 9a of adjacent light-emitting mini LED displays 9 remain connected to one another by the connecting ends.
[0125] According to the embodiment shown in Figures 15 to 22, in which the support circuit board 10 has a groove 18 that defines the boundary of the support portion 25, the method includes a step of forming the groove 18 on the second surface 10b of the support circuit board 10 during pre-preparation of the support board 10, i.e., prior to bonding the support board 10 to the inner wall 8.
[0126] The method may further include fixing the lighting device to the wall of the support frame 5, positioning the support frame 5 coupled to the small LED lighting device inside the shell 2, fixing the support frame 5 to the shell 2, firmly coupling the mask frame 7 to the support frame 2, and coupling the lens body 3 to the opening of the shell 2.
[0127] The above-described automotive lighting device and method for manufacturing the lighting device have many advantages.
[0128] Because Mini LEDs have a much smaller pitch than lighting fixtures made with conventional LED matrices or segmented OLEDs, using the Mini LED electronic modules in the Mini LED lighting devices makes it possible to produce lighting devices with relatively high resolution at relatively reduced cost.
[0129] The structure of the mini LED lighting device described above allows the mini LED lighting device to conform to three-dimensional shapes and thus follow the complex curvature profile of the lighting device.
[0130] The Mini LED electronic module incorporating the driver for manufacturing the light-emitting Mini LED display is useful for manufacturing automotive lighting devices with different shapes and sizes. In other words, the modular Mini LED lighting device can simplify the manufacturing process of the lighting device while not affecting manufacturing costs, since a common pick-and-place manufacturing process can be used to implement the driver and the Mini LED matrix. Additionally, because the control electronics, i.e., the driver, are applied directly on the Mini LED lighting device and can operate standalone, each Mini LED electronic module can be activated as if it were a separate electronic element.
[0131] This allows for the analysis and improvement of the thermodynamic and electronic performance of mini LED electronic modules.
[0132]
[0006] Embodiments that include forming grooves on the support substrate further simplify manufacturing, allowing for further simplification of the process and further reduction of manufacturing costs. Furthermore, the formation of cooling holes increases the space for the SMD elements on the second surface of the support circuit substrate, and promotes heat dissipation. This allows for the production of a light-emitting surface that is very tightly attached to the support circuit substrate and reduces the thickness, i.e., the bulk, of the mini LED lighting device within the lighting device.
[0133] Furthermore, in situations where modules are interconnected in a daisy chain, communication using a serial communication protocol between different LED drivers allows for a reduction in the number of messages / data sent from the electronic control unit 200 to the LED drivers 14 to create an image.
[0134] Furthermore, in the lighting device a constant pitch is maintained over the entire light-emitting surface, especially at the articulation points.
Claims
1. An automotive lighting device (1) comprising an inner wall (4) and a mini LED lighting device (6) coupled to the inner wall (4), A support circuit board (10) formed by one or more support portions (25), A plurality of flat mini LED electronic modules (11) are firmly bonded to one or more support portions (25) of the support circuit board (10) in a row, so as to form a light-emitting surface (8) configured to emit light, Automotive lighting device (1), including
2. The automotive lighting device (1) according to claim 1, wherein the mini LED electronic module (11) is coupled to one or more of the support portions (25) of the support circuit board (10) in order to form a light-emitting surface (8) having a predetermined three-dimensional shape.
3. Automotive lighting device (1) according to claim 1, wherein the inner wall (4) has a three-dimensional shape, and one or more support portions (25) of the support circuit board (10) are coupled to the inner wall (4) such that the mini LED electronic module (11) forms a light-emitting surface (8) having a three-dimensional shape corresponding to the three-dimensional shape of the inner wall (4).
4. Each of the mini LED electronic modules (11) is A flat circuit base (12) having a first surface firmly fixed to the first surface (10a) of the support circuit board (10), and a second surface opposite to the first surface, A mini LED array (13) is provided on the second surface of the circuit base (12) and comprises a plurality of mini LEDs having a predetermined pitch relative to each other. An LED driver (14) is firmly disposed on the first surface of the circuit base (12) and is electrically connected to the mini LED array (13) of the mini LED electronic module (11), Includes, The automotive lighting device (1) according to claim 3, wherein the LED driver (14) is configured to control the mini LED array (13).
5. Automotive lighting device (1) according to claim 4, wherein a cooling through-hole (26) is obtained on the support circuit board (10) that is positioned and sized to house each of the LED drivers (14) of the mini LED electronic module (11).
6. The mini LED electronic module (11) has a polygonal shape, Each of the mini LED electronic modules (11) has at least one outer surface (11a) which is substantially in contact with the outer surface (11a) of an adjacent mini LED electronic module (11), Automotive lighting device (1) according to claim 1, wherein the mini LEDs (6a) arranged along the contacting outer surface (11a) of the mini LED electronic module (11) have a pitch with respect to the corresponding mini LEDs (6a) arranged along the corresponding contacting outer surface (11a) of the adjacent mini LED electronic module (11), and the pitch is equal to the preset pitch of the remaining mini LEDs (6a).
7. The automotive lighting device (1) according to claim 4, wherein the support circuit board (10) supports a plurality of mini LED electronic modules (11) so as to lie on their respective lateral surfaces which are inclined relative to each other at a predetermined angle corresponding to the predetermined three-dimensional shape, and consists of a plurality of support portions (25) arranged side by side.
8. Each of the support portions (25) and the corresponding mini LED electronic module (11) forms a light-emitting mini LED display (9). The automotive lighting device (1) according to claim 7, wherein the light-emitting mini LED display (9) is adjacent to at least one other light-emitting mini LED display (9) and has at least one outer surface (9a) that is in contact with the outer surface (9a) of the other light-emitting mini LED display (9).
9. Automotive lighting device (1) according to claim 8, wherein the outer surfaces (9a) of adjacent light-emitting mini LED displays (9) that are in contact with each other have inclined flat walls seated relative to each other, and each inclined flat wall lies on a plane inclined at an angle corresponding to the three-dimensional shape predetermined with respect to the lateral surface of the corresponding light-emitting mini LED display (9).
10. The outer surfaces (9a) of at least two adjacent light-emitting mini LED displays (9) that are in contact with each other are connected to each other by connection ends obtained on the support circuit board (10), Automotive lighting device (1) according to claim 8 or 9, wherein the connecting end is configured to allow partial rotation of the light-emitting mini-LED display (9) along a linear common folding line (LP) that substantially coincides with the mutually contacting outer surfaces (9a) of two adjacent light-emitting mini-LED displays (9) with respect to the other light-emitting mini-LED display (9).
11. The automotive lighting device (1) according to claim 10, wherein the connecting end is obtained on the support circuit board (10) along a common folding line (LP) by a groove (18) extending on the second surface (10b) of the support circuit board (10) facing the first surface (10a).
12. The automotive lighting device (1) according to claim 1, wherein the mini LED lighting device (6) does not include a liquid crystal panel.
13. A method for manufacturing an automotive lighting device (1) comprising an inner wall (4) and a mini LED lighting device (6), The steps include providing a flat support circuit board (10) having one or more support portions (25), The steps include providing multiple flat mini LED electronic modules (11), The steps include: firmly fixing the flat mini LED electronic module (11) to one or more of the support portions (25) of the support circuit board (10) in a row, In order to form a light-emitting surface (8) suitable for emitting light, the steps include: connecting one or more of the support portions (25) of the support circuit board (10) to the inner wall (4), Methods that include...
14. The method according to claim 13, comprising the step of bonding the flat mini LED electronic module (11) to one or more of the support portions (25) of the support circuit board (10) so as to form a light-emitting surface (8) having a pre-set three-dimensional shape.
15. The method according to claim 13 or 14, wherein the inner wall (4) has a three-dimensional shape, and the method includes the step of connecting one or more of the support portions (25) of the support circuit board (10) to the inner wall (4) in order to position the flat mini LED electronic module (11) at a location such that a light-emitting surface (8) having a three-dimensional shape corresponding to the three-dimensional shape of the inner wall (4).