Method for preparing lamp assembly, extrusion device, lamp assembly and motor vehicle

Abstract

The present invention discloses a method for preparing a lamp assembly. The method comprises: continuously conveying a printed circuit board and a plurality of light sources through an extrusion device in a first direction; forming a light transparent layer on the plurality of light sources and the printed circuit board using a first extrusion apparatus; and forming an light emitting layer on the light transparent layer using a second extrusion apparatus, wherein the light transparent layer is configured such that light from the plurality of light sources propagates in the light transparent layer to a surface of the light transparent layer which faces the light emitting layer, and the light emitting layer is configured to receive and outwardly radiate the light from the light transparent layer, wherein before the light emitting layer is formed, at least one light diffusion structure is arranged on the surface of the light transparent layer.

Description

Method for preparing lamp assembly, extrusion device, lamp assembly and motor vehicle

[0001] The present invention relates to a method for preparing a lamp assembly, an extrusion device, a lamp assembly and a motor vehicle.

[0002] In an arrangement of a vehicle lamp assembly comprising a plurality of light sources, light from the light sources passes through an interior structure of the vehicle lamp assembly and is transmitted to the outside, so as to achieve an illumination effect. In a vehicle lamp assembly prepared by an extrusion process in the prior art, in a scenario in which the number of light sources and size of the assembly are restricted, the uniformity of optical distribution and the illumination effect are unable to satisfy actual requirements in some regions.Summary of the Invention

[0003] The objects of the present invention are to provide a lamp assembly, a method for preparing the lamp assembly, an extrusion device and a motor vehicle. The lamp assembly is prepared by an extrusion process, and a light diffusion structure may be formed in the preparation process, thereby improving optical distribution uniformity and reducing costs.

[0004] In one aspect, a method for preparing a lamp assembly using an extrusion device is provided, the extrusion device comprising a first extrusion apparatus and a second extrusion apparatus arranged in sequence in a first direction, and the method comprising: continuously conveying a printed circuit board and a plurality of light sources arranged on the printed circuit board through the extrusion device in the first direction; forming a light transparent layer on the plurality of light sources and the printed circuit board using the first extrusion apparatus; and forming an light emitting layer on the light transparent layer using the second extrusion apparatus, wherein the light transparent layer is configured such that light from the plurality of light sources propagates in the light transparent layer to a surface of the light transparent layer which faces the light emitting layer, and the light emitting layer is configured to receive and outwardly radiate the light from the light transparent layer, wherein before the light emitting layer is formed, at least one light diffusion structure is arranged on the surface of the light transparent layer.

[0005] In one embodiment, an air layer is formed between the light emitting layer and the at least one light diffusion structure.

[0006] In one embodiment, the light transparent layer is formed to comprise a main body part, which contacts the plurality of light sources and the printed circuit board, and a rolling part which is arranged on the main body part; and after the light transparent layer is extruded and before the light transparent layer is cured, an embossing apparatus is used to press the rolling part to form the at least one light diffusion structure.

[0007] In one embodiment, the rolling part is centrally arranged on the main body part in a second direction which is transverse to the first direction.

[0008] In one embodiment, after the light transparent layer is cured and before the light emitting layer is formed, the at least one light diffusion structure, which has been prepared in advance, is fitted to the surface of the light transparent layer.

[0009] In one embodiment, the light diffusion structure is formed to comprise a support part, which contacts the light transparent layer, and a diffusion part, which is on the support part and arranged centrally relative to the support part in the second direction which is transverse to the first direction, wherein the support part is formed to have the same width as the light transparent layer in the second direction.

[0010] In one embodiment, the support part (510) is adhered to the light transparent layer (30).

[0011] In one embodiment, the method further comprises: using the first extrusion apparatus to form a reflective layer which supports the printed circuit board and the light transparent layer, and the reflective layer being configured to guide the light from the plurality of light sources to radiate out from the surface of the light transparent layer.

[0012] In one embodiment, the at least one light diffusion structure is arranged such that the at least one light diffusion structure is in one-to-one correspondence with the plurality of light sources, wherein each said light source is centrally arranged below the corresponding light diffusion structure.

[0013] In one embodiment, the light diffusion structure comprises a tooth shape array structure or a pillow shape array structure.

[0014] In another aspect, an extrusion device for preparing a lamp assembly is provided, the extrusion device comprising: a first extrusion apparatus, the first extrusion apparatus being configured to form a light transparent layer on a printed circuit board and a plurality of light sources arranged on the printed circuit board; and a second extrusion apparatus, the second extrusion apparatus being configured for forming an light emitting layer on the light transparent layer, wherein the extrusion device further comprises: an embossing apparatus, the embossing apparatus being configured to press at least one light diffusion structure on a surface of the light transparent layer which faces the light emitting layer, before the light emitting layer is formed; or a light diffusion structure supply apparatus, the light diffusion structure supply apparatus being configured to fit at least one light diffusion structure, which is preformed, on the surface of the light transparent layer which faces the light emitting layer, before the light emitting layer is formed.

[0015] In one embodiment, the first extrusion apparatus comprises a first extrusion port, the first extrusion port being used for extruding a light transparent material to form the light transparent layer, and the embossing apparatus or the light diffusion structure supply apparatus being located downstream of the first extrusion port.

[0016] In one embodiment, the first extrusion apparatus further comprises a curing apparatus close to the first extrusion port, and the embossing apparatus is located between the curing apparatus and the first extrusion port, wherein the curing apparatus is located between the embossing apparatus and the second extrusion apparatus, or the curing apparatus is located downstream of the second extrusion apparatus.

[0017] In one embodiment, the first extrusion apparatus further comprises a curing apparatus which is downstream of the first extrusion port, and the light diffusion structure supply apparatus is located downstream of the curing apparatus.

[0018] In one embodiment, the first extrusion apparatus further comprises a second extrusion port, the second extrusion port is arranged on a side of the printed circuit board which is opposite the first extrusion port, and the second extrusion port is configured to form the reflective layer on outer sides of the printed circuit board and the light transparent layer.

[0019] In another aspect, a lamp assembly is provided, the lamp assembly comprising: a printed circuit board and a plurality of light sources arranged on the printed circuit board; a light transparent layer, the light transparent layer being arranged on the printed circuit board and the plurality of light sources, and the plurality of light sources being located between the light transparent layer and the printed circuit board; and an light emitting layer, the light emitting layer being arranged on the light transparent layer, wherein the light transparent layer is configured such that light from the plurality of light sources propagates in the light transparent layer to a surface of the light transparent layer which faces the light emitting layer, and the light emitting layer is configured to receive and outwardly emit the light from the light transparent layer, wherein at least one light diffusion structure is arranged on the surface of the light transparent layer which faces the light emitting layer.

[0020] In one embodiment, the light transparent layer is formed by an extrusion process; the at least one light diffusion structure is pressed on the light transparent layer, or the at least one light diffusion structure is bonded to the light transparent layer; the light emitting layer is formed by an extrusion process; the at least one light diffusion structure is arranged such that an air layer is formed between the at least one light diffusion structure and the light emitting layer.

[0021] In one embodiment, the at least one light diffusion structure is arranged centrally relative to the light transparent layer in a second direction which is transverse to the first direction.

[0022] In one embodiment, the lamp assembly further comprises a reflective layer, and the reflective layer is arranged to surround at least a portion of the light transparent layer and the printed circuit board, and supports the printed circuit board and the light transparent layer.

[0023] In one embodiment, the light emitting layer contacts the light transparent layer and the reflective layer, respectively, at two sides in the second direction, so as to cooperate with the reflective layer to fix the light transparent layer; or the light emitting layer contacts the at least one light diffusion structure and the reflective layer, respectively, at two sides in the second direction, so as to cooperate with the reflective layer to fix the at least one light diffusion structure and the light transparent layer.

[0024] In one embodiment, the lamp assembly further comprises a marking layer, and the marking layer is located at one side of the printed circuit board facing away from the light transparent layer, and penetrates through the reflective layer in the first direction.

[0025] In one embodiment, the plurality of light sources are arranged equidistant from each other on the printed circuit board, and the at least one light diffusion structure comprises a plurality of light diffusion structures which are arranged in one-to-one correspondence with the plurality of light sources, wherein each said light source is centrally arranged below the corresponding light diffusion structure.

[0026] In one embodiment, the size of each said light diffusion structure is greater than 1 mm; and / or the light transparent layer (30) is made of a fully light transparent silicone rubber material; and / or the light emitting layer (40) is made of a light translucent silicone rubber material, and the light emitting layer is used for diffusing light.

[0027] In another aspect, a motor vehicle is provided, the motor vehicle comprising the lamp assembly according to an embodiment of the present invention.Brief Description of the Drawings

[0028] shows a schematic drawing of a preparation sequence for a lamp assembly according to an embodiment of the present invention.

[0029] shows a longitudinal sectional drawing of a lamp assembly according to an embodiment of the present invention.

[0030] shows a schematic drawing of an extrusion device according to an embodiment of the present invention.

[0031] shows a transverse sectional drawing of a lamp assembly prepared using the extrusion device shown inaccording to an embodiment of the present invention.

[0032] shows a schematic drawing of an extrusion device according to another embodiment of the present invention.

[0033] shows a transverse sectional drawing of a lamp assembly prepared using the extrusion device shown inaccording to an embodiment of the present invention.Detailed Description of Embodiments

[0034] The technical solution of the present invention is explained in further detail below by means of embodiments, in conjunction with the accompanying drawings. In this description, identical or similar reference signs denote identical or similar components. The following explanation of embodiments of the present invention with reference to the accompanying drawings is intended to explain the overall inventive concept of the present invention, and should not be interpreted as a limitation of the present invention.

[0035] In addition, in the following detailed description, to facilitate explanation, many specific details are expounded to provide a comprehensive understanding of the embodiments of the present disclosure. However, it is obvious that one or more embodiments may also be implemented without these specific details.

[0036] shows a schematic drawing of a preparation sequence for a lamp assembly 100 according to an embodiment of the present invention.shows a longitudinal sectional drawing of a lamp assembly 100 according to an embodiment of the present invention.shows a schematic drawing of an extrusion device 200 according to an embodiment of the present invention.shows a transverse sectional drawing of a lamp assembly 100 prepared using the extrusion device 200 shown inaccording to an embodiment of the present invention.

[0037] According to an embodiment of the present invention, the extrusion device 200 may be used to prepare the lamp assembly 100. As shown in Figs. 1 - 3, the extrusion device 200 may comprise a first extrusion apparatus 210 and a second extrusion apparatus 220 which are arranged in sequence in a first direction D1. A printed circuit board 10 and a plurality of light sources 20 which are arranged on the printed circuit board 10 may be continuously conveyed through the extrusion device 200 in the first direction D1, so as to prepare the lamp assembly 100 using corresponding material layers formed on the printed circuit board 10 and the plurality of light sources 20 by means of the extrusion device 200.

[0038] As an example, the printed circuit board 10 may be a flexible printed circuit board. The light source 20 may be a light-emitting diode (LED). However, the embodiments of the present invention are not limited to this, and according to actual needs, the light source 20 may be any light source capable of emitting light.

[0039] As shown in Figs. 1 and 3, the printed circuit board 10 and the plurality of light sources 20 may first be conveyed through the first extrusion apparatus 210 in the first direction D1, so as to form a light transparent layer 30 on the printed circuit board 10 and the plurality of light sources 20 using the first extrusion apparatus 210. As an example, the light transparent layer 30 may be formed from a fully light transparent material, such as a fully light transparent silicone rubber material. However, the embodiments of the present invention are not limited to this.

[0040] Specifically, the first extrusion apparatus 210 may be provided with a first extrusion port 2101 opposite the side of the printed circuit board 10 which is provided with the light sources 20. The light transparent material used to form the light transparent layer 30 may enter a feed port which corresponds to the first extrusion port 2101, and is pushed to the first extrusion port 2101, so as to be extruded from the first extrusion port 2101 and laid on the printed circuit board 10 and the plurality of light sources 20. Thus, the light transparent layer 30 is formed on the printed circuit board 10 and the plurality of light sources 20, and the plurality of light sources 20 may be located between the light transparent layer 30 and the printed circuit board 10. As shown in, the light transparent layer 30 may be formed to fully contact the printed circuit board 10 and the light sources 20.

[0041] As shown in Figs. 1 and 3, the first extrusion apparatus 210 may further be provided with a second extrusion port 2102. The second extrusion port 2102 may be arranged at one side of the printed circuit board 10 which is opposite the first extrusion port 2101, so as to form the reflective layer 60 on outer sides of the printed circuit board 10 and the light transparent layer 30. As an example, the reflective layer 60 may be formed from a fully opaque material, such as a fully opaque silicone rubber material. The reflective layer 60 can reflect the light from the light source 20 to the light transparent layer 30 and / or the light emitting layer 40. However, the embodiments of the present invention are not limited to this. According to an embodiment of the present invention, the reflective material used to form the reflective layer 60 may enter a feed port which corresponds to the second extrusion port 2102, and is pushed to the second extrusion port 2102, so as to be extruded from the second extrusion port 2102 and form the reflective layer 60.

[0042] As shown in, the reflective layer 60 may be formed to surround at least a portion of the printed circuit board 10 and the light transparent layer 30 from the outside. That is, the reflective layer 60 may be formed at one side of the printed circuit board 10 which is opposite the light transparent layer 30, and covers at least a portion of the printed circuit board 10. The reflective layer 60 may extend upwards respectively at both sides of the printed circuit board 10 in a second direction D2 which is transverse to the first direction D1, so as to cover at least a portion of the light transparent layer 30 on both sides in the second direction D2, so as to surround the light transparent layer 30 from side faces of the light transparent layer 30. In this way, the reflective layer 60 may support the printed circuit board 10 and the light transparent layer 30. The reflective layer 60 may fully contact the printed circuit board 10 and the light transparent layer 30.

[0043] According to an embodiment of the present invention, the light transparent layer 30 and the reflective layer 60 may be simultaneously extruded in the first extrusion apparatus 210, or the light transparent layer 30 and the reflective layer 60 may be extruded sequentially one after the other. This may be adjusted according to actual requirements. According to characteristics of the extrusion process, the extrusion port is generally designed to have a specific shape, so that extrusion material may be extruded in said specific shape, and then the extruded material is cured to form said specific shape. Therefore, according to an embodiment of the present invention, according to the required positional relationships between the printed circuit board 10, the light sources 20, the light transparent layer 30 and the reflective layer 60, the shapes of the first extrusion port 2101 and the second extrusion port 2102 may be respectively correspondingly designed. In a scenario in which the first extrusion port 2101 and the second extrusion port 2102 are combined together, the light transparent layer 30 and the reflective layer 60 may be formed simultaneously. In a scenario in which the first extrusion port 2101 and the second extrusion port 2102 are arranged in a staggered manner, the light transparent layer 30 and the reflective layer 60 are extruded one after the other, and the extrusion sequence may be adjusted according to actual requirements; for example, first the light transparent layer 30 is extruded, then the reflective layer 60 is extruded.

[0044] In addition, according to characteristics of the extrusion process, a curing apparatus is generally further provided close to the extrusion port, for quickly curing and setting an extruded layer, so as to maintain the formed shape. According to an embodiment of the present invention, a curing apparatus may be provided close to the first extrusion port 2101 and the second extrusion port 2102, to cure and set the extruded light transparent layer 30 and reflective layer 60.

[0045] Next, the conveying process may continue through the second extrusion apparatus 220, so as to form the light emitting layer 40 on the light transparent layer 30 using the second extrusion apparatus 220. That is, the light emitting layer 40 is formed on one side of the light transparent layer 30 which is opposite the printed circuit board 10. As an example, the light emitting layer 40 may be formed from a light translucent material, such as a light translucent silicone rubber material, so that the diffuse reflection of light may occur in the light emitting layer 40, to enhance a scattering illumination effect of light. However, the embodiments of the present invention are not limited to this.

[0046] Specifically, the second extrusion apparatus 220 may be provided with a third extrusion port 2103. The third extrusion port 2103 may be arranged on the same side as the first extrusion port 2101 opposite the printed circuit board 10, for forming the light emitting layer 40 on the light transparent layer 30. According to an embodiment of the present invention, the material used to form the light emitting layer 40 may enter from a feed port which corresponds to the third extrusion port 2103, and is pushed to the third extrusion port 2103, so as to be extruded from the third extrusion port 2103 and form the light emitting layer 40.

[0047] In some embodiments, the curing apparatus 2100 may be located between an embossing apparatus 300 and the second extrusion apparatus 220; in this case, another curing apparatus (not shown) may be provided downstream of the second extrusion apparatus 220 for curing the light emitting layer 40. In other embodiments, the curing apparatus 2100 may be directly arranged downstream of the second extrusion apparatus 220, and a unified curing step is performed after all the extrusion steps have been completed.

[0048] As shown in, the light emitting layer 40 is formed to cover the light transparent layer 30, and contacts the light transparent layer 30 and the reflective layer 60, respectively, at both sides in the second direction D2 which is transverse to the first direction D1. Therefore, the positional relationships of the light transparent layer 30, the light emitting layer 40 and the reflective layer 60 are such that the light emitting layer 40 and the reflective layer 60 contact each other at said both sides of the light transparent layer 30, which causes the reflective layer 60 to further support the light emitting layer 40 while supporting the printed circuit board 10 and the light transparent layer 30. Moreover, at the position of contact between the light emitting layer 40 and the reflective layer 60, the light emitting layer 40 further contacts the light transparent layer 30, which allows the light emitting layer 40 to apply a fixing action force to the light transparent layer 30 with the aid of the support of the reflective layer 60. In this way, the light emitting layer 40 may cooperate with the reflective layer 60, to fix the light transparent layer 30 on the printed circuit board 10 and the light source 20, to achieve tight contact between the three, thereby improving the product quality and service life of the lamp assembly 100. As described above, the third extrusion port 2103 may be designed to have a specific shape, so that the light emitting layer 40 is extruded with a desired shape.

[0049] The first extrusion apparatus 210 may further be provided with a fourth extrusion port. The fourth extrusion port may be located on the same side as the second extrusion port 2102 opposite the printed circuit board 10, for extruding a marking layer 70. As described above, the positional relationship and shapes of the second extrusion port 2102 and the fourth extrusion port may be designed according to the desired positional relationship between the marking layer 70 and the reflective layer 60. As an example, as shown in, the marking layer 70 may be formed at one side of the printed circuit board 10 which faces away from the light transparent layer 30, and may penetrate through the reflective layer 60 in the first direction D1. This allows the marking layer 70 to directly contact the printed circuit board 10. According to an embodiment of the present invention, the marking layer 70 may be formed from the same material as the light transparent layer 30. That is, the marking layer 70 may also be formed from a fully light transparent material, such as a fully light transparent silicone rubber material. However, the embodiments of the present invention are not limited to this. In this way, by means of a light transparent effect of the marking layer 70, cut marks on the printed circuit board 10 may be seen, which is advantageous for a convenient and accurate cutting process in a cutting stage after a curing stage, thereby accelerating production progress and saving on costs.

[0050] According to an embodiment of the present invention, before the light emitting layer 40 is formed, at least one light diffusion structure 50 may be arranged on a surface S of the light transparent layer 30 which faces the light emitting layer 40. As an example,shows a plurality of light diffusion structures 50. However, the embodiments of the present invention are not limited to this; for example, only one continuous whole light diffusion structure 50 may be arranged on the surface S of the light transparent layer 30, or the number of light diffusion structures 50 may be adjusted according to actual requirements. Herein, “light diffusion structure” may indicate a structure which causes light passing therethrough to scatter, thereby broadening an irradiation range of the light. Especially, the light diffusion structures 50 can diffuse the light along the first direction D1.

[0051] As shown in Figs. 2 and 4, according to the lamp assembly 100 of an embodiment of the present invention, in a scenario in which the plurality of light sources 20 are powered on to emit light, light L from the light sources 20 propagates in the light transparent layer 30 to the surface S of the light transparent layer 30, and is emitted outward from the surface S. As described above, the reflective layer 60 is arranged to surround the light transparent layer 30 from an outer side, and is formed from a fully opaque material; therefore, the reflective layer 60 may guide the light L toward the surface S of the light transparent layer 30, so as to be emitted outward from the surface S. According to an embodiment of the present invention, since the light diffusion structure 50 is provided on the surface S of the light transparent layer 30, at least some of the light L from the light sources 20 is emitted via the light diffusion structure 50. Next, the light emitting layer 40 may receive the light L from the light transparent layer 30, and emit the light outward to achieve an illumination effect.

[0052] In this way, in one aspect, the light diffusion structure 50 may be used to broaden the irradiation range of the light L emitted from the light source 20, such that the irradiation ranges of the light L emitted by adjacent light sources 20 may overlap each other, thereby ensuring the lamp assembly 100 is fully lit up, without dark zones which are not irradiated, providing a desired optical distribution uniformity. In another aspect, by means of arranging the light diffusion structure 50, the distances between the light sources 20 may be further widened, and it is not necessary to arrange the light sources 20 close to each other to avoid illumination dark zones. This may save on costs. In a further aspect, the height of the lamp assembly 100 in the direction which is perpendicular to the first direction D1 and the second direction D2 may further be reduced, and it is not necessary to deliberately increase the height of the lamp assembly 100 in order to increase the light ray range to enlarge the light irradiation range. This allows the lamp assembly 100 to weigh less and saves on costs, and to be more flexibly adapted to a surrounding structure in a vehicle body for example.

[0053] According to an embodiment of the present invention, in the process of forming the light emitting layer 40, an air layer 80 is formed between the light emitting layer 40 and the light diffusion structure 50 on the light transparent layer 30. As shown in Figs. 2 and 4, the light emitting layer 40 is arranged to not directly contact the light transparent layer 30 and the light diffusion structure 50 on the light transparent layer 30, and is separated therefrom by a certain distance, thereby forming the air layer 80.

[0054] In this way, by means of providing the air layer 80, the scattering effect of the light diffusion structure 50 may be ensured, to present an effect of a broadened light irradiation range. Due to a difference in refractive index between an air medium in the air layer 80 and the material forming the light transparent layer 30 and the light diffusion structure 50, when the light L is emitted from the light transparent layer 30 and the light diffusion structure 50 into the air layer 80, the phenomenon of refraction occurs, and therefore the path of advance of the light L is deflected which broadens the irradiation range. Further, due to the scattering characteristics of the light diffusion structure 50 itself, the light L emitted from the light diffusion structure 50 may be deflected at various angles, which further broadens the irradiation range, such that the irradiation ranges of adjacent light sources 20 may overlap each other.

[0055] As an example, by means of correspondingly designing the shape of the third extrusion port 2103 which is used for forming the light emitting layer 40, the air layer 80 may be formed while forming the light emitting layer 40. For example, a hollowed-out design may be applied to a portion which corresponds to the light emitting layer 40, and a solid design is applied to a portion corresponding to the air layer 80. Thus, when the material of the light emitting layer 40 is extruded from the third extrusion port 2103, the material may pass through the hollowed-out portion but may not pass through the solid portion, so as to form the light emitting layer 40 with a corresponding shape via the hollowed-out portion, and leave the solid portion to act as the air layer 80. In addition, for the height of the air layer 80 in the direction which is perpendicular to the first direction D1 and the second direction D2 (that is, the distance of separation between the light emitting layer 40 and the light diffusion structure 50), a suitable design may be applied according to actual illumination effect and / or actual lamp assembly size requirements.

[0056] In an embodiment, the light transparent layer 30 may be formed to comprise a main body part 310, which contacts the plurality of light sources 20 and the printed circuit board 10, and a rolling part 320 which is arranged on the main body part 310. After extruding the light transparent layer 30 and before curing the light transparent layer 30, an embossing apparatus 300 is used to press or imprint the rolling part 320 to form the at least one light diffusion structure 50. In the present embodiment, the rolling part 320 protrudes from the main body part 310, which allows the light diffusion structure 50 to be conveniently formed.

[0057] As shown in, the extrusion device 200 may comprise the embossing apparatus 300. As an example, as shown in, the embossing apparatus 300 may be a round rotating apparatus, and an outer peripheral surface of the embossing apparatus 300 is provided with an imprinting pattern. For example, when the light transparent layer 30 is extruded from the first extrusion port 2101, and the light transparent layer 30 is continuously conveyed in the first direction D1, the embossing apparatus 300 may continuously rotate, and the outer peripheral surface of the embossing apparatus 300 may contact a portion of the light transparent layer 30; for example, the outer peripheral surface of the embossing apparatus 300 may contact the rolling part 320 of the light transparent layer 30, and may press said portion of the light transparent layer 30 according to the imprinting pattern on the embossing apparatus 300, so as to shape the light transparent layer 30 according to the shape of the imprinting pattern, so as to form a light diffusion structure 50, with the same shape as the imprinting pattern, on the surface S of the light transparent layer 30.

[0058] However, the embodiments of the present invention are not limited to this. Embossing apparatuses 300 of other shapes are also conceivable, as long as a specific shape may be pressed on the light transparent layer 30 extruded from the first extrusion port 2101. In addition, the frequency at which the embossing apparatus 300 imprints the pattern on the light transparent layer 30 and the length of the imprinted pattern may also follow different designs according to actual structural requirements of the light diffusion structure 50.

[0059] As an example, as shown in, the embossing apparatus 300 may be comprised in the first extrusion apparatus 210, and is located downstream of the first extrusion port 2101. In addition, the first extrusion apparatus 210 further comprises a curing apparatus 2100 close to the first extrusion port 2101, and the embossing apparatus 300 is located between the first extrusion port 2101 and the curing apparatus 2100. Therefore, according to an embodiment of the present invention, when the light transparent layer 30 has been extruded from the first extrusion port 2101 but before curing the light transparent layer 30, the embossing apparatus 300 may be used to form the light diffusion structure 50 on the surface S of the light transparent layer 30.

[0060] Generally, according to characteristics of an extrusion process, extrusion material extruded from an extrusion port is in a soft state, and is then shaped into a solid state via a curing apparatus, so that a finished product is extruded from the extrusion apparatus. Therefore, it is necessary to perform the pressing process on the light transparent layer 30 when the light transparent layer 30 is in the soft state, in order to easily shape the surface S of the light transparent layer 30. In such a scenario, the embossing apparatus 300 is arranged between the first extrusion port 2101 and the curing apparatus 2100. Thus, after the light transparent layer 30 in the soft state has been extruded from the first extrusion port 2101, the embossing apparatus 300 is used to press the light transparent layer 30 in the soft state to form the light diffusion structure 50, and then curing and shaping are performed via the curing apparatus 2100, so that a light transparent layer 30 with a surface S having at least one light diffusion structure 50 is extruded from the first extrusion apparatus 210.

[0061] Although inthe curing apparatus 2100 is shown to be located between the embossing apparatus 300 and the second extrusion apparatus 220, this is merely an example. In another embodiment, as described above, the curing apparatus 2100 also may be arranged to be located downstream of the second extrusion apparatus 220, so that a unified curing step is performed after all the extrusion steps have been completed.

[0062] As an example, as shown in, the light transparent layer 30 may be formed to comprise the main body part 310 and the rolling part 320. The main body part 310 is arranged to contact the printed circuit board 10, the light sources 20 and the reflective layer 60. The rolling part 320 is arranged on one side of the main body part 310 which faces away from the light sources 20. In the pressing process of the embossing apparatus 300, the embossing apparatus 300 may be configured to press the rolling part 320 of the light transparent layer 30, so as to form the light diffusion structure 50 in the rolling part 320. In this way, different structural designs of the light diffusion structure 50 may be facilitated, so as to be readily suited to different application requirements.

[0063] In an embodiment, the rolling part 320 may be centrally arranged on the main body part 310 in the second direction D2. As shown in, the rolling part 320 may be located in a middle position relative to the main body part 310, such that the rolling part 320 also does not contact the light emitting layer 40 in the second direction D2. In this way, after the light diffusion structure 50 is formed via the rolling part 320, light emitted from the light diffusion structure 50 is also enabled to undergo path deflection in the second direction D2 and achieve a scattering effect, thereby ensuring an illumination effect of a portion of the light emitting layer 40 in the second direction D2. In addition, by means of centrally arranging the rolling part 320, the light emitting layer 40 is enabled to also contact the main body part 310 of the light transparent layer 30 at the position where the light emitting layer contacts the reflective layer 60. As described above, this allows the light emitting layer 40 to cooperate with the reflective layer 60 to fix the light transparent layer 30, thereby increasing the structural stability of the lamp assembly 100.

[0064] shows a schematic drawing of an extrusion device 200 according to another embodiment of the present invention.shows a transverse sectional drawing of a lamp assembly 100 prepared using the extrusion device 200 shown inaccording to an embodiment of the present invention.

[0065] In one embodiment, after the light transparent layer 30 is cured and before the light emitting layer 40 is formed, the at least one light diffusion structure 50, which has been prepared in advance, may be fitted to the surface S of the light transparent layer 30. In this embodiment, as shown in, the extrusion device 200 may comprise a light diffusion structure supply apparatus 400, and using the light diffusion structure supply apparatus 400, as opposed to the embossing apparatus 300 shown in, at least one light diffusion structure 50 is arranged on the surface S of the light transparent layer 30.

[0066] According to an embodiment of the present invention, the differences between the extrusion device 200 inand the extrusion device 200 inonly lie in a portion of the first extrusion apparatus 210 which is used for extruding the light transparent layer 30, and the light diffusion structure supply apparatus 400. Therefore, the portion of the extrusion device 200 which is the same as inis not shown in; only the portion different tois shown. However, it should be noted that the extrusion device 200 in the embodiment shown inmay comprise the same portions shown infor forming the reflective layer 60 and the marking layer 70 (comprising the second extrusion port 2102 and the fourth extrusion port), and the portion for forming the light emitting layer 40 (comprising the third extrusion port 2103).

[0067] As an example, as shown in, the light diffusion structure supply apparatus 400 may comprise a plurality of light diffusion structures 50 which are prepared in advance, and may supply the light diffusion structures 50 to the surface S of the light transparent layer 30 according to a certain frequency, so as to fit the light diffusion structures 50 on the surface S. Unlike the embossing apparatus 300 in, the light diffusion structures 50 supplied by the light diffusion structure supply apparatus 400 are components prepared in advance with complete and fixed structures. Therefore, assembly of the light diffusion structure 50 and the light transparent layer 30 is a type of physical joining of two components. In such a scenario, it is necessary to join the light diffusion structure 50 to the light transparent layer 30 after the latter has cured to complete the assembly process. Thus, the light diffusion structure supply apparatus 400 is arranged downstream of the curing apparatus 2100 of the first extrusion apparatus 210. After the light transparent layer 30 has been extruded from the first extrusion port 2101, the light transparent layer 30 is first cured and set via the curing apparatus 2100, and then at least one light diffusion structure 50 is arranged on the surface S via the light diffusion structure supply apparatus 400, so as to form the light transparent layer 30 having the light diffusion structure 50. Preferably, the light diffusion structure supply apparatus 400 may be arranged between the first extrusion apparatus 210 and the second extrusion apparatus 220. However, the embodiments of the present invention are not limited to this.

[0068] By using the light diffusion structure supply apparatus 400, the light diffusion structures 50 may be more flexibly arranged on the light transparent layer 30. For example, the light diffusion structure supply apparatus 400 may comprise light diffusion structures 50 of various forms, and a supply frequency may be set more freely. This allows the extrusion device 200 to be applied to processing various types of lamp assembly, and the structures and sizes of the light diffusion structures 50 may be easily modified as needed according to design and application requirements.

[0069] In one embodiment, the light diffusion structure 50 may be formed to comprise a support part 510, which contacts the light transparent layer 30, and a diffusion part 520, which is on the support part 510 and arranged centrally relative to the support part 510 in the second direction D2, wherein the support part 510 is formed to have the same width as the light transparent layer 30 in the second direction D2. In another embodiment, the width of the support part 510 may also be less than the width of the light transparent layer 30, and the light emitting layer 40 directly abuts the light transparent layer 30.

[0070] As shown in Figs. 5 and 6, the light diffusion structures 50, which are prepared in advance and supplied by the light diffusion structure supply apparatus 400, may comprise support parts 510 and the diffusion parts 520. The support part 510 is configured to contact the light transparent layer 30 and the reflective layer 60. The diffusion part 520 is arranged on one side of the support part 510 which faces away from the light sources 20, for the purpose of emitting light outward. The support part 510 is configured to have the same width as the light transparent layer 30 extending in the second direction D2, such that the support part 510 may completely cover the light transparent layer 30 in the second direction D2, thus contacting the reflective layer 60 at two sides. In this way, the support part 510 may have the maximum area of contact with the light transparent layer 30, thereby ensuring stability of the physical joining between the two and improving the product quality of the lamp assembly.

[0071] In addition, the diffusion part 520 is configured to emit light outward, and has a scattering effect. Therefore, the diffusion part 520 may be prepared in advance in a specific shape, to form the light diffusion structure. The diffusion part 520 inmay correspond to the rolling part 320 having been pressed and cured in. In such a scenario, similar to the rolling part 320, the diffusion part 520 may also be arranged centrally relative to the support part 510, and therefore also centrally relative to the light transparent layer 30. As described above, in this way, while ensuring the illumination effect of the light emitting layer 40 at two sides in the second direction D2, the light emitting layer 40 is also permitted to contact the support part 510 at the position where the light emitting layer contacts the reflective layer 60, so as to cooperate with the reflective layer 60 to press and fix the support part 510 of the light diffusion structure 50, thereby further ensuring the structural stability of the lamp assembly 100 and ensuring the illumination effect and optical distribution uniformity. In the present embodiment, the diffusion part 520 protrudes from the support part 510.

[0072] In one embodiment, the support part 510 of the light diffusion structure 50 may be bonded or adhered to the light transparent layer 30. For example, adhesive may be provided on the bottom of the support part 510, and then the support part 510 is fitted to the light transparent layer 30 using the adhesive effect of the adhesive, thereby completing the arrangement of the light diffusion structure 50 on the light transparent layer 30. However, the embodiments of the present invention are not limited to this; other joining means may be considered, as long as the support part 510 is able to be stably held on the light transparent layer 30.

[0073] In one embodiment, the plurality of light sources 20 may be equidistantly arranged on the printed circuit board 10. The at least one light diffusion structure 50 may comprise a plurality of light diffusion structures 50 which are arranged in one-to-one correspondence with the plurality of light sources 20. As shown in, by means of arranging the plurality of light sources 20 equidistantly on the printed circuit board 10, the irradiation ranges of the light sources 20 may be made equal to each other, which is advantageous for the uniformity of the illumination effect of the lamp assembly 100. Further, by means of arranging the plurality of light diffusion structures 50 in one-to-one correspondence with the plurality of light sources 20, the optical distribution uniformity of the lamp assembly 100 may be further improved and increased. In such a scenario, the light emitted from the light sources 20 is all emitted outward via the corresponding light diffusion structure 50, such that the irradiation ranges of the light sources 20 are all broadened. Thus, the irradiation ranges of adjacent light sources 20 overlap each other, so that the whole lamp assembly 100 is able to light up, without the presence of dark zones of no passing light on the light emitting layer 40. Therefore, the lamp assembly 100 according to an embodiment of the present invention has a superior optical distribution uniformity and a good illumination effect, and the preparation process is simple, flexibility is high, and operation and execution are easy.

[0074] Preferably, each light diffusion structure 50 may be arranged such that the light sources 20 are arranged centrally relative to the corresponding light diffusion structure 50. In this way, the irradiation ranges of the light sources 20 may be broadened to the maximum extent, to ensure the uniformity of the illumination effect.

[0075] Preferably, the size of each light diffusion structure 50 may be greater than 1 mm.

[0076] In one embodiment, the light diffusion structure 50 may comprise a tooth shape array structure or a pillow shape array structure. However, the embodiments of the present invention are not limited to this; light diffusion structures arranged in other suitable shapes may be comprised according to actual requirements.

[0077] Although the present invention has been explained in conjunction with the accompanying drawings, the embodiments disclosed in the accompanying drawings are intended to provide an exemplary illustration of preferred embodiments of the present invention, and must not be interpreted as a limitation of the present invention.

[0078] Although some embodiments of the overall concept of the present invention have been shown and explained, those skilled in the art will understand that changes may be made to these embodiments without departing from the principles and spirit of the overall inventive concept. The scope of the present invention is defined by the claims and their equivalents.

Claims

Method for preparing a lamp assembly (100) using an extrusion device (200), the extrusion device (200) comprising a first extrusion apparatus (210) and a second extrusion apparatus (220) which are arranged in sequence in a first direction (D1), characterized in that the method comprises:conveying a printed circuit board (10) and a plurality of light sources (20) which are arranged on the printed circuit board (10) continuously through the extrusion device (200) in the first direction (D1);using the first extrusion apparatus (210), forming a light transparent layer (30) on the plurality of light sources (20) and the printed circuit board (10); andusing the second extrusion apparatus (220), forming an light emitting layer (40) on the light transparent layer (30),wherein the light transparent layer (30) is configured such that light (L) from the plurality of light sources (20) propagates in the light transparent layer (30) to a surface (S) of the light transparent layer (30) which faces the light emitting layer (40), and the light emitting layer (40) is configured to receive and outwardly radiate the light (L) from the light transparent layer (30),wherein before the light emitting layer (40) is formed, at least one light diffusion structure (50) is arranged on the surface (S) of the light transparent layer (30).Method according to Claim 1, characterized in that the method further comprises:forming an air layer (80) between the light emitting layer (40) and the at least one light diffusion structure (50);forming the light transparent layer (30) to comprise a main body part (310), which contacts the plurality of light sources (20) and the printed circuit board (10), and a rolling part (320) which is arranged on the main body part (310); andafter extruding the light transparent layer (30) and before curing the light transparent layer (30), using an embossing apparatus (300) to press the rolling part (320) to form the at least one light diffusion structure (50);centrally arranging the rolling part (320) on the main body part (310) in a second direction (D2) which is transverse to the first direction (D1).Method according to Claim 1, characterized in that the method further comprises:after the light transparent layer (30) is cured and before the light emitting layer (40) is formed, fitting the at least one light diffusion structure (50), which has been prepared in advance, to the surface (S) of the light transparent layer (30);forming the light diffusion structure (50) to comprise a support part (510), which contacts the light transparent layer (30), and a diffusion part (520), which is on the support part (510) and arranged centrally relative to the support part (510) in a second direction (D2) which is transverse to the first direction (D1),wherein the support part (510) is formed to have the same width as the light transparent layer (30) in the second direction (D2);the fitting step comprises: adhering the support part (510) onto the light transparent layer (30).Method according to any one of Claims 1 - 3, characterized in that the method further comprises: using the first extrusion apparatus (210) to form a reflective layer (60) which supports the printed circuit board (10) and the light transparent layer (30), and the reflective layer (60) being configured to guide the light (L) from the plurality of light sources (20) to radiate out from the surface (S) of the light transparent layer (30).Method according to any one of Claims 1 - 3, characterized in that the method comprises:arranging the at least one light diffusion structure (50) such that the at least one light diffusion structure (50) is in one-to-one correspondence with the plurality of light sources (20), wherein each said light source (20) is centrally arranged below the corresponding light diffusion structure (50);the light diffusion structure (50) comprises a tooth shape array structure or a pillow shape array structure.Extrusion device (200) for preparing a lamp assembly (100), characterized in that the extrusion device (200) comprises:a first extrusion apparatus (210), the first extrusion apparatus (210) being configured to form a light transparent layer (30) on a printed circuit board (10) and a plurality of light sources (20) arranged on the printed circuit board (10); anda second extrusion apparatus (220), the second extrusion apparatus (220) being configured to form an light emitting layer (40) on the light transparent layer (30),wherein the extrusion device (200) further comprises:an embossing apparatus (300), the embossing apparatus (300) being configured to press at least one light diffusion structure (50) on a surface (S) of the light transparent layer (30) which faces the light emitting layer (40), before the light emitting layer (40) is formed; ora light diffusion structure supply apparatus (400), the light diffusion structure supply apparatus (400) being configured to fit at least one light diffusion structure (50), which is preformed, onto the surface (S) of the light transparent layer (30) which faces the light emitting layer (40), before the light emitting layer (40) is formed.Extrusion device (200) according to Claim 6, characterized in that the first extrusion apparatus (210) comprises a first extrusion port (2101), the first extrusion port being used for extruding a light transparent material to form the light transparent layer (30), and the embossing apparatus (300) or the light diffusion structure supply apparatus (400) being located downstream of the first extrusion port (2101).Extrusion device (200) according to Claim 7, characterized in that the first extrusion apparatus (210) further comprises a curing apparatus (2100) close to the first extrusion port (2101), and the embossing apparatus (300) is located between the curing apparatus (2100) and the first extrusion port (2101),wherein the curing apparatus (2100) is located between the embossing apparatus (300) and the second extrusion apparatus (220), or the curing apparatus (2100) is located downstream of the second extrusion apparatus (220).Extrusion device (200) according to Claim 7, characterized in that the first extrusion apparatus (210) further comprises a curing apparatus (2100) which is downstream of the first extrusion port (2101), and the light diffusion structure supply apparatus (400) is located downstream of the curing apparatus (2100).Extrusion device (200) according to Claim 7, characterized in that the first extrusion apparatus (210) further comprises a second extrusion port (2102), the second extrusion port (2102) is arranged on a side of the printed circuit board (10) which is opposite the first extrusion port (2101), and the second extrusion port (2102) is configured to form the reflective layer (60) on outer sides of the printed circuit board (10) and the light transparent layer (30).Lamp assembly (100), characterized in that the lamp assembly (100) comprises:a printed circuit board (10) and a plurality of light sources (20) which are arranged on the printed circuit board (10);a light transparent layer (30), the light transparent layer (30) being arranged on the printed circuit board (10) and the plurality of light sources (20), and the plurality of light sources (20) being located between the light transparent layer (30) and the printed circuit board (10); andan light emitting layer (40), the light emitting layer (40) being arranged on the light transparent layer (30),wherein the light transparent layer (30) is configured such that light (L) from the plurality of light sources (20) propagates in the light transparent layer (30) to a surface (S) of the light transparent layer (30) which faces the light emitting layer (40), and the light emitting layer (40) is configured to receive and outwardly radiate the light (L) from the light transparent layer (30),wherein at least one light diffusion structure (50) is provided on the surface (S) of the light transparent layer (30) which faces the light emitting layer (40).Lamp assembly (100) according to Claim 11, characterized in that the light transparent layer (30) is formed by an extrusion process;the at least one light diffusion structure (50) is pressed on the light transparent layer (30), or the at least one light diffusion structure (50) is bonded to the light transparent layer (30);the light emitting layer (40) is formed by an extrusion process; andthe at least one light diffusion structure (50) is arranged such that an air layer (80) is formed between the at least one light diffusion structure (50) and the light emitting layer (40).Lamp assembly (100) according to Claim 11, characterized in that the at least one light diffusion structure (50) is arranged centrally relative to the light transparent layer (30) in a second direction (D2) which is transverse to the first direction (D1);the lamp assembly (100) further comprises a reflective layer (60), and the reflective layer (60) is arranged to surround at least a portion of the light transparent layer (30) and the printed circuit board (10), and supports the printed circuit board (10) and the light transparent layer (30).Lamp assembly (100) according to Claim 13, characterized in that the light emitting layer (40) contacts the light transparent layer (30) and the reflective layer (60), respectively, at two sides in the second direction (D2), so as to cooperate with the reflective layer (60) to fix the light transparent layer (30); orthe light emitting layer (40) contacts the at least one light diffusion structure (50) and the reflective layer (60), respectively, at two sides in the second direction (D2), so as to cooperate with the reflective layer (60) to fix the at least one light diffusion structure (50) and the light transparent layer (30).Lamp assembly (100) according to any one of Claims 11 - 14, characterized in that the plurality of light sources (20) are arranged equidistant from each other on the printed circuit board (10), and the at least one light diffusion structure (50) comprises a plurality of light diffusion structures (50) which are arranged in one-to-one correspondence with the plurality of light sources (20), wherein each said light source (20) is centrally arranged below the corresponding light diffusion structure (50);the size of each said light diffusion structure (50) is greater than 1 mm; and / orthe light transparent layer (30) is made of a fully light transparent silicone rubber material; and / orthe light emitting layer (40) is made of a light translucent silicone rubber material, and the light emitting layer is used for diffusing light.

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