ES2831300T3 - Vehicle light equipped with at least one light source of the light-emitting diode type and mounting method for the same - Google Patents

Abstract

Vehicle light (4) comprising - a container body (8) and a lenticular body (12) defining at least partially a housing chamber (16) housing a light-emitting diode light source (20), - said light emitting diode light source (20) comprising an electrical support and a connection component (28) having electrical connection means (32) and at least one support wall (36), - the source of light diode (20) at least one light emitting diode (40) electrically connected to the electrical connection means (32), - the light emitting diode (40) comprising a substrate (44) fixed to the wall of support (36) and an encapsulation (48), associated with a chip (102) in order to project projecting from said support wall (36), for a maximum distance (L), characterized in that - the light (4) It comprises guide and junction means (52) for the diode light source (20) defining at least one housing seat (56) at least for Partially shaped opposite the electrical support and connecting component (28). - in which the guide and connection means (52) comprise at least one front wall (60) oriented directly towards the encapsulation (48), so that the distance (D) measured perpendicular between the front wall (60) and the support wall (36) is from 1 to 2.5 times the maximum distance (L), - in which the vehicle light (4) comprises at least one protection device (50) attached to the support wall (36 ) at least partially around said encapsulation (48), in which the height (H) of said protection device (50), measured perpendicular to the support wall (36) is from 1 to 2.5 times the maximum distance (L), said protection device (50) being suitable to allow the insertion of the diode light source (20) in the housing seat (56), in order to avoid any impact or contact between the encapsulation (48 ) and the front wall (60) in the step of inserting the diode light source (20) in the respective housing seat (56), wherein the housing seat (56) has an access hole (64) for the light emitting diode (40), located laterally in relation to the front wall (60) in order to identify an insertion direction (XX ) of the light emitting diode (40) parallel to the front wall (60) and perpendicular to the projecting part of the encapsulation (48), in which the guide and connection means (52) comprise a pair of rails (68) that project from said front wall (60) towards the diode light source (20), the rails (68) being parallel to the insertion direction (XX) of the diode (40) and being located in such a way that, in a mounted configuration of the vehicle light (4), surround and perimeter contain the protection device (50).

Description

DESCRIPTION

Vehicle light equipped with at least one light source of the light-emitting diode type and mounting method for the same

The present invention relates to a vehicle light provided with at least one light source of the light-emitting diode type, called LED, in which the term vehicle light independently refers to a rear vehicle light or a vehicle light front, the latter also called a projector or headlight. The present invention also relates to a method of mounting such a vehicle light.

As is known, a vehicle light is a lighting and / or signaling device comprising at least one exterior light of the vehicle that has a function of lighting or signaling outside the vehicle. A vehicle light, taken in its simplest form, comprises a container body, a lenticular body, and at least one light source.

The lenticular body is positioned in order to close the mouth of the container body in order to form a housing chamber. The light source is arranged within the housing chamber, which can be oriented in order to emit light towards the lenticular body, when it is supplied with electricity.

The light emitting diode light source comprises an electrical support and a connecting component for mechanically supporting and electrically connecting electronic components and at least one electronic component composed of a light emitting diode.

The electrical support and the connection component can be composed, for example, of a rigid, rigid-flexible or flexible printed circuit, while a normal light emitting diode comprises a plate of a semiconductor circuit material, the so-called "chip" and an encapsulation.

The encapsulation may further include an optical element which is generally composed of a silicone resin lens or an epoxy resin lens, which encompasses a conductive wire, the so-called wire bonding. Conventional light emitting diode light sources are vulnerable to mechanical stress, such as impact, friction wear, and the like which can compromise the integrity of the light emitting diode encapsulation.

In fact, the light emitting diode light source may be subject to improper mounting manipulations during the vehicle light mounting stage, which can lead to separation of the silicone resin lens or damage to the lead wire or the semiconductor board.

As a result, the light emitting diode may be broken or damaged. In the case where the light-emitting diode is broken, the formation of light is always affected, while, in the case where the light-emitting diode is damaged, the formation of light can be suspended under certain conditions of difficult to identify during testing or the durability of the light emitting diode may be reduced.

Think, for example, of the case where the lead wire moves out of its original position. In this case, the light emitting diode may work during testing but stops working under certain conditions or prematurely.

As a consequence of this fact, the production rejections or the returns within the warranty regarding the light of the vehicle increase considerably, thus affecting the final production costs. As an example of a conventional vehicle light, FR2955530 describes a luminous vehicle glazing that incorporates a light emitting diode light source and has all the features of the preamble of claim 1 of the present invention.

The aim of the present invention is to provide a vehicle light provided with at least one light source of the light-emitting diode type capable of ensuring greater reliability and of avoiding breakage of the diode light source during mounting of the light.

Such an objective is achieved by a vehicle light according to claim 1 and by a mounting method according to claim 15.

Other embodiments of the vehicle light according to the invention are described in the subsequent claims. Additional features and advantages of the present invention will be more clearly understood from the description given below of its preferred and non-limiting embodiments, in which:

Figure 1 is a perspective view of separated parts of a vehicle light according to an embodiment of the invention;

Figure 2 shows a perspective view of some components of the light in Figure 1;

figure 3 shows an enlargement of detail III in figure 2;

Figure 4 shows a cross-sectional view along sectional plane IV-IV in Figure 3; figure 5 shows a perspective view of a detail of the light according to the present invention;

Figures 6 to 7 respectively show a plan view and a side view of detail VI in Figure 5; Figure 8 is a partial cross section of a detail of a light according to an embodiment of the present invention;

figure 9 shows a plan view of the detail in figure 8;

Figure 10 is a partial cross section of a detail of a light according to an embodiment of the present invention;

figure 11 shows a plan view of the detail in figure 10;

Common elements or parts of elements in the embodiments described below will be indicated using the same reference numerals.

With reference to the figures mentioned above, reference number 4 globally indicates a vehicle light; the definition of vehicle light is to be understood in a general sense, comprising a light suitable for use in any type of motorized vehicle.

The vehicle light 4 comprises a container body 8 and a lenticular body 12 that at least partially defines a housing chamber 16 that houses a light-emitting diode 20 light source.

The container body 8 comprises a mouth 10 through which it normally receives and contains the various components of the light; the container body 8 also allows the connection of the light 4 to the respective vehicle. The lenticular body 12 is made of a partially transparent, semi-transparent, or translucent material and may also include an opaque portion.

The lenticular body 12 is positioned in order to close the mouth 10 of the container body 8 in order to enclose said housing chamber 16.

Additional vehicle light components 4 may be placed within the housing chamber 16 such as, for example, a reflector body 22, a collimating body (not shown), and a light guide body 24. The reflector body 22 is made usually of an opaque material and is substantially concave in shape with one of its inner surfaces mirrored, ie metallized. The reflector body 22 is further coupled to the light source, in order to form an optical system in which the light emitted by the light source 20 is reflected onto the interior metallized surface of the reflector body 22 and is projected to a great distance after crossing the lenticular body 12.

The collimating body is normally made of transparent material and bases its working principle on the physical phenomenon of refraction. The collimating body is positioned adjacent to the light source to collect and propagate the light emitted by the light source therein. The light propagated within the collimating body is therefore emitted in the form of a substantially concentrated beam of light in a predetermined projection zone or point.

The collimating body is normally made of transparent material and bases its working principle on the physical phenomenon of refraction that regulates the transmission of light within optical fibers. The light guide body 24 is positioned next to the light source, in order to collect and propagate the light emitted by the light source therein. The light propagated within the light guide body 24 is then distributed in the surrounding space in a desired manner. The light guide body 24 may further be fitted with a plurality of light deflection / extraction elements to deflect / extract light propagated therein out of said light guide body.

The light emitting diode light source 20 comprises an electrical support and a connection component 28 having electrical connection means 32 and at least one support wall 36.

The electrical support and connection component 28 can typically be composed of a rigid printed circuit, a rigid-flexible printed circuit or a flexible printed circuit, depending on the type of application. The electrical connection means 28 are composed, for example, of electrical contacts, cables, tracks applied to the printed circuit, suitable for electrically connecting electronic components.

The diode light source 20 further comprises at least one light emitting diode 40 electrically connected to the electrical connection means 32.

According to one embodiment, the light emitting diode 40 comprises a substrate, or package, 44 fixed to the support wall 36 and an encapsulation 48, which encompasses a chip 102 in order to project projecting from said support wall 36, for a maximum distance "L".

The package 48 comprises an optical element such as, for example, a silicone resin lens or an epoxy resin lens.

The encapsulation 48 is positioned so as to encompass the chip 102 and a conductive wire, the so-called wire joint, thereby performing a dual function of projection from foreign bodies and of directing a luminous flux emitted by the chip 102.

Advantageously, the vehicle light 4 comprises at least one protection device 50 attached to the support wall 36 at least partially around said encapsulation 48, as further described below.

Light 4 comprises guiding and attachment means 52 for diode light source 20 defining at least one housing seat 56 at least partially shaped opposite electrical support and connecting component 28.

The guiding and joining means 52 comprise at least one front wall 60 facing directly towards the encapsulation 48 so that the distance D measured perpendicular between the front wall 60 and the support wall 36 is from 1 to 2.5 times the maximum distance. 'L'; preferably said distance D is from 1.3 to 1.7 times the maximum distance 'L'.

According to one embodiment, the guide and attachment means 52 identify a housing seat 56 having an access hole 64 for the light emitting diode 40, located laterally in relation to the front wall 60 in order to identify an insertion direction. XX of the light emitting diode 40 substantially parallel to the front wall 60 and perpendicular to the projecting portion of the package 48.

In other words, the light emitting diode 40 is inserted laterally to the front wall 60 so that the package is directed perpendicular to the X-X insertion direction.

According to one embodiment, the guide and junction means 52 comprise a pair of rails 68 projecting from said front wall 60 towards the diode light source 20, the rails 68 being parallel to the insertion direction XX of the diode 40 and being positioned in such a way that, in a mounted configuration of the light, they surround and perimeter contain the protection device 50.

Preferably, the guide and attachment means 52 comprise a pair of clamps 72, positioned opposite the front wall 60 in order to lock in place the electrical support and the connecting component 28, positioned between the clamps 72 and the front wall. 60 according to an interference coupling.

In other words, clamp 72 and / or rails 68 guide the insertion of electrical support and connecting component 28 into housing seat 56 and, once inserted, ensure that it locks in place.

In particular, the clamps 72, the rails 68 and / or the front wall 60 receive an insertion end 76 of the electrical support and the connection component 28 and guide the component as well as the respective limit stop in the housing seat 56.

According to one embodiment, the guide and junction means 52 for the light source 20 make it possible to insert the electrical support and the connecting component 28, so that the light produced by the light emitting diode 40 is directly received and transmitted by the light receiving and propagating element of the vehicle light 4, such as the collimator body, the light guide body 24 or the lenticular body 12 described above.

According to one embodiment, so that the light produced by the light emitting diode 20 is received directly and transmitted by the light receiving and propagating element of the vehicle light 4, such as the collimator body, the guide body of lumen 24 or lenticular body 12 described above. In other words, the guide and connection means 52 are located next to the light reception and propagation element, in order to allow the light emitting diode 40 to be arranged next to said light reception and propagation element for avoid scattering of the emitted light beam.

In one embodiment, so that the light produced by the light emitting diode 20 is received directly and transmitted by the light receiving and propagating element of the vehicle light 4, such as the collimator body, the guide body of lumen 24 or lenticular body 12 described above.

For example, a light guide body 24 is shown in the figures, which ends at a first end with said guide and link means 52 in order to house at least one light emitting diode.

As mentioned above, advantageously, the vehicle light 4 of the present invention comprises at least one protection device 50 attached to the support wall 36 at least partially around said encapsulation 48, in order to protect the encapsulation 48 from any contact / impact against the front wall 60.

A height H of said protection device 50, measured perpendicular to the support wall 36, is from 0.8 to 2.5 times the maximum distance 'L' and, preferably, the height H of said protection device 50 is from 1 to 2.5 times the maximum distance 'L' and, in any case, compatible with the distance 'D' as further specified below, in order to allow the insertion of the diode light source 20 into the housing seat 56 and avoid any impact or contact between the encapsulation 48 and the front wall 60 in the stage of inserting the diode light source 20 into the respective housing seat 56, according to the insertion direction XX imposed by the means guide and union 52.

According to a preferred embodiment, the protection device 50 is at least partially glued and / or welded to the supporting wall 36.

To facilitate soldering, the shield 50 is preferably fitted with at least one metal terminal 92 suitable for soldering to the supporting wall 36, according to prior art methods, for example, by means of known SMT surface mount technology. or, equivalently, SMD in which no drilling of the electrical support and connecting component is performed.

According to one embodiment, the protection device 50 can be attached to the supporting wall 36 in a removable way. For example, the support wall 36 may comprise a through hole 80 and the guard 50 may comprise at least one attachment tooth 84 suitable for making snap-lock engagement with said through hole 80. For example, the locking tooth joint 84 may comprise a chamber 86 to facilitate insertion into through hole 80; a wedge 88 of the attachment tooth 84 may thereby form a recess in the through hole 80, on the side opposite the support wall 36, in order to lock it.

According to a further embodiment, the protection device 50 is fitted with at least one metal pin 96 inserted in the through hole 80 of the electrical support and the connection component 28 and riveted on the opposite side to the support wall 36.

According to one embodiment, the protection device 50 is fitted with at least one protection wall 100 located on the side of an insertion end 76 of the light emitting diode 40 in the respective housing seat 56, said protection wall 100 being located between insertion end 76 and package 48 along insertion direction XX, in order to avoid contact between package 48 and front wall 60 during insertion of diode 40 into housing seat 56.

For example, the at least one shield wall 100 of shield device 50 extends along a closed line that completely surrounds light emitting diode 40.

For example, the protection wall 100 extends along a quadrangular, circular, elliptical perimeter: obviously any additional geometric shape can also be contemplated.

The shield wall 100 of the shield device 50 is positioned and dimensioned such that it leaves a beam of light emitted by the light emitting diode 40 unaltered when the light source of the light emitting diode 20 is powered by electricity.

In other words, the height H and the distance of the protection wall 100 from the encapsulation 48 are chosen so as not to interfere with the light beam emitted by the diode 40. More specifically, the height H of the protection wall depends on the amplitude a of a light beam emitted by a light-emitting diode, so that the protection wall 100 does not alter said light beam. For example, a formula for the height H of the protective wall in relation to the amplitude a might be the following:

H = K c or tg (of / 2)

in which the constant K represents the parameters imposed by the topology of the circuit.

Obviously, the choice of the value H must meet the requirements of non-interference with the front wall 60 explained above in order to allow the insertion of the diode light source 20 in the housing seat 56: in other words, the height H must be less than or equal to D.

According to a further embodiment, the protection device 50 comprises a box-shaped protective cover 104 that is substantially transparent or semi-transparent to light, said box-shaped protective cover 104 covering the chip 102 and the package 48.

For example, said box-shaped protective cover 104 is hemispherical. Furthermore, said box-shaped protective cover 104 may comprise at least one hole in the encapsulation 48: thereby promoting heat exchange of diode 40 and reducing interference with the light beam produced by diode 40 as much as possible.

The method of mounting a vehicle light according to the invention will now be described.

In particular, the container body 8 and the lenticular body 12 defining at least partially the housing chamber 16 are prepared to house at least one light-emitting diode 20 source. At least one light-emitting diode source is prepared. light 20 comprising an electrical support and a connection component 28 having electrical connection means 32 and at least one support wall 36 and comprising at least one light emitting diode 40 electrically connected to the electrical connection means 32. The light emitting diode 40 comprises, as seen, a substrate 44 fixed to the support wall 36 and the package 48, attached to the chip 102 in order to project projecting from the support wall 36, for a distance maximum (L).

The method further comprises the step of providing guiding and attachment means 52 for the diode light source 20 defining at least one housing seat 56 shaped at least partially opposite the electrical support and connecting component 28, in whereby the guide and connection means 52 comprise at least one front wall 60 facing directly towards the encapsulation 48 so that the distance D measured perpendicular between the front wall 60 and the support wall 36 is from 1 to 2.5 times the maximum distance L. Preferably, said distance D is from 1 to 2.5 times the maximum distance 'L'.

It is advantageously contemplated the connection of at least one protection device 50 to the support wall 36 at least partially around said encapsulation 48, in which the height H of said protection device 50, measured perpendicular to the support wall 36, it is from 1 to 2.5 times the maximum distance L and in any case compatible with the distance 'D'.

The protection device 50 can be of any shape or size according to the previous description.

After connecting the protection device 50 to the diode 40, the diode light source 20 is inserted into the housing seat 56 through the guide and junction means 52, in order to avoid any impact or contact between the package. 48 and front wall 60 during said insertion step.

Preferably, the insertion of the diode light source 20 into the housing seat 56 takes place through the guide and attachment means 64, located laterally in relation to the front wall 60 in order to identify an insertion direction XX of the light emitting diode 40 substantially parallel to the front wall 60 and perpendicular to the projecting portion of the package 48.

As can be appreciated from the description, the vehicle light according to the invention makes it possible to overcome the presented disadvantages of the prior art.

In fact, the light emitting diode and, in particular, the encapsulation, which constitutes the most delicate element, is protected from impact / collision at all times during the light assembly stage.

In this way, diode breakage and damage are avoided and as a result production rejects and warranty returns in relation to the vehicle light are drastically reduced, thereby also reducing final production costs.

The protection devices according to the present invention not only make it possible to protect the most sensitive parts of the light emitting diode but also do not substantially interfere with the light optics of the vehicle: in other words, it does not modify the light beam produced.

In addition, the protection devices allow adequate thermal exchange of the diode with the environment, such as to avoid possible overheating of the diode.

One skilled in the art can make numerous modifications and variations to the vehicle lights described above to meet specific and contingent requirements, all contained within the scope of the invention as defined by the appended claims.

Claims (15)

1. Vehicle light (4) comprising - a container body (8) and a lenticular body (12) defining at least partially a housing chamber (16) housing a light-emitting diode light source (20), - said light emitting diode light source (20) comprising an electrical support and a connection component (28) having electrical connection means (32) and at least one support wall (36), - the diode light source (20) further comprising at least one light emitting diode (40) electrically connected to the electrical connection means (32), - the light emitting diode (40) comprising a substrate (44) fixed to the support wall (36) and an encapsulation (48), associated with a chip (102) in order to project projecting from said support wall ( 36), for a maximum distance (L), characterized because - the light (4) comprises guiding and joining means (52) for the diode light source (20) defining at least one housing seat (56) at least partially shaped opposite the electrical support and the connecting component (28). - in which the guide and connection means (52) comprise at least one front wall (60) oriented directly towards the encapsulation (48), so that the distance (D) measured perpendicular between the front wall (60) and the support wall (36) is from 1 to 2.5 times the maximum distance (L), - in which the vehicle light (4) comprises at least one protection device (50) attached to the support wall (36) at least partially around said encapsulation (48), in which the height (H) of said protection device (50), measured perpendicular to the support wall (36) is from 1 to 2.5 times the maximum distance (L), said protection device (50) being adequate to allow the insertion of the source of diode light (20) in the housing seat (56), in order to avoid any impact or contact between the encapsulation (48) and the front wall (60) in the insertion stage of the diode light source ( 20) in the respective housing seat (56), wherein the housing seat (56) has an access hole (64) for the light emitting diode (40), located laterally in relation to the front wall (60) in order to identify an insertion direction (XX ) of the light emitting diode (40) parallel to the front wall (60) and perpendicular to the projecting part of the package (48), wherein the guide and attachment means (52) comprise a pair of rails (68) projecting from said front wall (60) toward the diode light source (20), the rails (68) being parallel to the insertion direction (XX) of the diode (40) and being located in such a way that, in a mounted configuration of the vehicle light (4), they surround and perimeter contain the protection device (50). Vehicle light (4) according to claim 1, in which the guiding and connecting means (52) comprise a pair of clamps (72), located opposite the front wall (60) in order to lock in place Place the electrical support and the connecting component (28), positioned between the clamps (72) and the front wall (60) in an interference fit. Vehicle light (4) according to any one of the preceding claims, wherein the guide and attachment means (52) for the light source (20) are directly attached to and / or oriented towards an element to receive and propagate the light from the vehicle light, such as a collimating body, a light guiding body (24), or a lenticular body (12). Vehicle light (4) according to any of the preceding claims, in which the attachment means for the light source (20) are in one piece with an element for receiving and propagating the light of the vehicle light, such as such as a collimating body, a light guiding body (24) or a lenticular body (12) of light (4). Vehicle light (4) according to any one of the preceding claims, wherein said protection device (50) is attached to the supporting wall (36) in a removable manner. Vehicle light (4) according to any of the preceding claims, wherein said supporting wall (36) comprises a through hole (80) and the protection device (50) comprises the least one connecting tooth (84) suitable for making a snap-lock engagement in said through hole (80). Vehicle light (4) according to any one of the preceding claims from 1 to 4, in which the protection device (50) is at least partially glued and / or welded to the supporting wall (36). Vehicle light (4) according to any of the preceding claims from 1 to 4, in which the protection device (50) is fitted with at least one metal pin (96) inserted in the electrical support and the connecting component (28) and riveted on the side opposite the support wall (36). Vehicle light (4) according to any of the preceding claims, in which the protection device (50) is provided with at least one protection wall (100) located on the side of an insertion end (76) of the light emitting diode (40) in the respective housing seat (56), said protection wall (100) being located between the insertion end (76) and the encapsulation along the insertion direction (XX), with in order to avoid contact between the encapsulation (48) and the front wall (60) during the insertion of the diode (40) in the housing seat (56). Vehicle light (4) according to claim 9, wherein the at least one protection wall (100) of the protection device (50) extends along a closed line that completely surrounds the light-emitting diode. (40). Vehicle light (4) according to claim 9 or 10, in which the protection wall (100) of the protection device (50) is positioned and dimensioned in such a way as to leave unaltered a beam of light emitted by the light-emitting diode (40) when the light-emitting diode (20) light source is powered by electricity. Vehicle light (4) according to any of the preceding claims from 1 to 10, in which the protection device (50) comprises a protective cover in the form of a box (104) substantially transparent or semi-transparent to light, covering said protective cover in the form of a box (104) the chip (102) and the package (48). A vehicle light (4) according to claim 12, wherein said box-shaped protective cover (104) is hemispherical. Vehicle light (4) according to claim 12 or 13, wherein said box-shaped protective cover (104) comprises at least one hole in the package (48). 15. Method of mounting a vehicle light according to any of claims 1 to 14, comprising the steps of: - preparing the container body (8) and the lenticular body (12) that define at least partially the housing chamber (16) to house a light-emitting diode light source (20), - preparing at least one light emitting diode light source (20) comprising an electrical support and a connection component (28) having electrical connection means (32) and at least one support wall (36), and comprising at least one light emitting diode (40) electrically connected to the electrical connection means (32), the light emitting diode (40) comprising a substrate (44) fixed to the supporting wall (36) and an encapsulation (48), associated with a chip (102) in order to project projecting from said support wall (36), for a maximum distance (L), - the method being characterized in that it comprises the steps of: - providing guiding and joining means (52) for the diode light source (20) defining at least one housing seat (56) shaped at least partially opposite to the electrical support and the connection component (28), comprising said guide and attachment means (52) to at least one front wall (60) oriented directly towards the encapsulation (48) so that the distance (D) measured perpendicular between the front wall (60) and the support wall (36) is from 1 to 2.5 times the maximum distance (L), - in which the guide and joining means (52) comprise a pair of rails (68) projecting from said front wall (60) towards the diode light source (20), the rails (68) being parallel to the insertion direction (XX) of the diode (40) and being located in such a way that, in a mounted configuration of the vehicle light (4), they surround and perimeter contain the protection device (50), - connecting at least one protection device (50) to the support wall (36), at least partially around said encapsulation (48), in which the height (H) of said protection device (50), measured perpendicular to the support wall (36) is from 1 to 2.5 times the maximum distance (L), - inserting the diode light source (20), previously fitted with the protection device (50), into the housing seat (56) through the guide and connection means (52), in order to avoid any impact or contact between the encapsulation (48) and the front wall (60) during said insertion stage, - providing an access hole (64) in the housing seat (56) for the diode (40), located laterally in relation to the front wall (60) in order to identify an insertion direction (XX) of the emitting diode of light (40) parallel to the front wall (60) and perpendicular to the projecting part of the encapsulation (48).