CN103162207A - Light-emitting diode (LED) unit installing module and manufacturing method thereof and LED lighting device and automobile headlamp - Google Patents

Light-emitting diode (LED) unit installing module and manufacturing method thereof and LED lighting device and automobile headlamp Download PDF

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Publication number
CN103162207A
CN103162207A CN2011104212212A CN201110421221A CN103162207A CN 103162207 A CN103162207 A CN 103162207A CN 2011104212212 A CN2011104212212 A CN 2011104212212A CN 201110421221 A CN201110421221 A CN 201110421221A CN 103162207 A CN103162207 A CN 103162207A
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China
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led
lines
portion
formed
housing
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CN2011104212212A
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Chinese (zh)
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钟海强
何海翔
曾思雄
徐小刚
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欧司朗股份有限公司
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Priority to CN2011104212212A priority Critical patent/CN103162207A/en
Publication of CN103162207A publication Critical patent/CN103162207A/en

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Abstract

The invention provides a light-emitting diode (LED) unit installing module which is used for achieving installation of an LED unit in application environment. The LED unit installing module (10) comprises a heat dissipation block (12) and a shell body (14) which is arranged outside the heat dissipation block (12), the LED unit is arranged on the heat dissipation block in an attached mode, and the shell body forms a connecting structure which is matched with a connecting structure in the application environment. The shell body in the process of forming of the shell body and the heat dissipation block form a whole. The invention further provides an LED lighting device using the LED unit installing module (10) and an automobile headlamp using an LED lighting device. The invention further provides a method manufacturing the LED unit installing module (10).

Description

LED单元安装模块及其制造方法、LED照明装置和汽车前照灯 LED unit mounting module and a manufacturing method, LED lighting device and the vehicle headlamp

技术领域 FIELD

[0001] 本申请涉及LED(发光二极管)照明装置、尤其是大功率LED照明装置中的LED单元安装模块、使用这种安装模块的LED照明装置、以及应用这种LED照明装置的汽车前照灯。 [0001] The present application relates to LED (light emitting diode) lighting devices, in particular high-power LED lighting apparatus of the LED module unit is installed, the LED lighting device using such a mounting module, and the application of such a vehicle headlamp LED lighting device . 本申请还涉及制造LED单元安装模块的方法。 The present application also relates to a method for manufacturing an LED module unit is installed.

背景技术 Background technique

[0002] 本部分提供了与本申请相关的背景信息,这些信息并不必然构成现有技术。 [0002] This section provides background information to the present application, such information does not necessarily constitute prior art.

[0003] 当前,在汽车的前向照明领域中,LED(发光二极管)作为一种新的光源已经逐渐得到应用。 [0003] Currently, the automobile prior to lighting, the LED (light emitting diode) as a new light has been increasingly applied. 目前在汽车前照灯中通常采用包含LED单元的LED照明装置。 Currently in commonly used vehicle headlamp lighting apparatus comprising LED LED unit. 其中,LED照明装置还包括有LED单元安装结构,借助于LED单元安装结构实现LED单元在应用环境中的安装。 Wherein, LED lighting device further comprises a mounting structure of the LED unit, the LED unit by means of mounting the LED unit mounting structure implemented in the application environment. 尤其是,在汽车前向照明应用环境下,为了获得适于汽车前向照明的亮度,需要使用大功率的LED单元。 In particular, in the automotive forward lighting application environment, in order to obtain the LED unit before the car is adapted to the brightness of the lighting, the power required. 然而,使用大功率的LED单元将产生大量的热。 However, the use of high-power LED unit generates much heat. 因而需要在不给汽车前照灯的其他装置及结构造成热影响的情况下为LED器件和/或LED器件与印刷电路板的组件提供良好的散热。 Thus a need to provide good heat dissipation for the LED device and an LED device or assembly / printed circuit board without causing thermal influence to other devices and structures of the vehicle headlamp. 为此,LED照明装置中需要包括有散热装置。 To this end, LED lighting device includes a heat sink is required. 在此方面,通常采用由外部塑料壳与中央散热块构成的LED单元安装组件来实现LED单元在应用环境中的安装并同时确保良好的散热。 In this regard, the LED unit mounting assembly usually made of plastic case and an external heat sink blocks to implement the central unit mounted LED application environment while ensuring good heat dissipation.

[0004] 图1和图2示出了目前所使用的一种示例性LED单元安装组件10'。 [0004] Figures 1 and 2 illustrate an exemplary mounting assembly 10 LED unit currently in use '. 该LED单元安装组件10'包括外部塑料壳14'和中央散热块12'。 The LED unit mounting assembly 10 'includes an outer plastic shell 14' and the central heat sink block 12 '. 外部塑料壳14'具有限定有通孔的圆筒部142'和位于圆筒部142'下端处的基部143'。 The outer plastic shell 14 'having a cylindrical portion defining a through hole 142' 'at the lower end of the base portion 143' and the cylindrical portion 142 is located. 在基部143'上形成有安装孔1431'。 'Is formed with a mounting hole 1431' at base 143. 中央散热块12'通常由诸如铝或铜的具有良好热传导性的金属材料制成,具有呈大致圆柱形的柱形部121'和设置于柱形部121'下端处的凸缘部122',凸缘部122'上形成有与基部143'的安装孔1431'配`对的安装孔1221'。 The central heat sink block 12 'is typically made of aluminum or a metal material having good thermal conductivity such as copper, having a substantially cylindrical columnar portion 121' and disposed in the cylindrical portion 121 'at the lower end of the flange portion 122', 'there is formed on the base 143' of the flange portion 122 of the mounting hole 1431 '' with the mounting holes of the 1221 '. 安装时,将中央散热块12'的柱形部121'插入外部塑料壳14'的通孔中并使中央散热块12'的凸缘部122'上的安装孔122Γ与外部塑料壳14'的基部143'上的安装孔143Γ对准、然后将螺钉16'拧紧至对准的基部安装孔1431'和凸缘部安装孔1221'中,从而将中央散热块12'固定至外部塑料壳14'上。 The flange portion 122 'of the cylindrical portion 121' is installed, the central heat slug 12 into the outer plastic case 14 'and the central through hole of the heat dissipation block 12' 'with the mounting holes on the outer plastic case 122Γ 14' base portion 143 '143Γ aligned mounting holes, then the screws 16' screwed to the base aligned mounting holes 1431 'and the flange portion of the mounting hole 1221', so that the center of the heat dissipation block 12 'fixed to the outer plastic shell 14' on. 使用时,LED单元(未图示)附装于中央散热块12'的柱形部121'侧的轴向端部上,通过形成在LED单元安装组件10'的外部塑料壳14'上的连接结构(未标号)与应用环境上的相应连接结构(未图示)的配合实现LED单元在应用环境中的安装。 When used, the LED unit (not shown) attached to the axial end of the center heat dissipating block 12 'of the cylindrical portion 121' side, the connection is formed by mounting the LED unit assembly 10 'of the outer plastic shell 14' mating structure (not numbered) and a respective connecting structure (not shown) mounted on the LED unit application environment implemented in the application environment.

[0005] 然而在上述情况下,所实现的中央散热块与外部塑料壳之间的固定并不足够稳定。 [0005] In the above case, however, achieved between the central heat sink block and the fixed outer plastic case is not sufficiently stable. 而中央散热块相对于外部塑料壳的微小松动都将导致连接在中央散热块一端处的LED单元中的LED器件偏离所需的位置,进而不能实现所需的光照输出。 While the central heat sink block with respect to a slight loosening of the outer plastic case will result in the LED unit is connected at the center of one end of the heat sink block in the LED device from a desired position, and thus can not achieve the desired light output. 因而在一些情况下,还可采用适当的胶粘剂将中央散热块固定至外部塑料壳上。 Thus, in some cases, it may be employed suitable adhesive to the center of the heat dissipation block is fixed on the outer plastic case. 此外,还可通过干涉配合的方式将中央散热块固定至外部塑料壳上。 Further, also by an interference fit manner to the central heat sink block is fixed on the outer plastic case.

[0006] 然而,通过胶粘或干涉配合的方式将中央散热块固定至外部塑料壳需要特定的程序且需要较大的公差,因而难以进行组装并且制造成本高。 [0006] However, by gluing or interference fit manner to the central heat sink block fixed to the outer plastic housing and requires a specific procedure requires large tolerances, it is difficult to assemble and costly to manufacture. 发明内容 SUMMARY

[0007] 鉴于以上问题,根据本申请的一方面,提供了一种LED单元安装模块,用于实现LED单元在应用环境中的安装。 [0007] In view of the above problems, according to an aspect of the present disclosure, there is provided an LED unit mounting means for mounting the LED unit implemented in the application environment. 所述LED单元安装模块可包括散热块和位于散热块外部的壳体。 The LED module may include a cooling unit mounting block and the heat sink block located outside of the housing. LED单元可附装于散热块上。 LED unit can be attached to the heat sink block. 壳体上形成有与应用环境中的连接结构相匹配的连接结构。 Forming a connection structure and connection structure that matches the application environment of the housing. 其中,壳体在该壳体的成形过程中与散热块形成为一体。 Wherein the housing and the heat dissipation block is formed in the forming process of the housing integrally. 根据这种构造,相比于目前常用的通过螺钉、胶粘剂或干涉配合的连接而言,可实现散热块与壳体之间更稳定、更紧密并且不松动的固定连接。 According to this configuration, compared to the commonly used by screws, adhesive or interference fit connection, it may be more stable between the heat sink block and the housing are not more closely and fixedly connected loose. 并且,可简化将散热块和壳体固定在一起的工艺,例如可减少对散热块与壳体进行固定连接所需的如螺钉、昂贵的胶粘剂的需求,降低构件的制造公差要求,从而使制造成本大大降低。 And simplify the heat dissipation block and the housing together processes, for example, reduce the heat dissipation block and the housing for fixing the connection requirements needed such as screws, adhesive expensive, reduce the manufacturing tolerance requirements of the member, thereby producing costs are significantly reduced.

[0008] 根据本申请的实施方式,壳体可通过包覆注塑而与散热块形成为一体。 [0008] According to embodiments of the present disclosure, the housing may be formed by coating the heat dissipation block integrally injection. 根据这种构造,由于可在单独的包覆注塑工序中在对壳体进行模制成形的同时将壳体模制到散热块上,因而壳体与散热块可非常紧密地固定在一起并且不松动。 According to this configuration, since the extrusion-coated in a separate step while the housing will be molded housing molded onto the heat sink block, and thus the housing and the heat dissipation block may be very close together and not loose. 另外,可减少构件的制造工序并降低构件的制造公差要求,从而可大大降低制造成本。 Further, the manufacturing process can be reduced to reduce manufacturing and component tolerances member, which can greatly reduce the manufacturing cost.

[0009] 根据本申请的实施方式,散热块的外表面上可具有第一接合部。 [0009] According to embodiments of the present disclosure, the outer surface of the heat dissipation block may have a first engagement portion. 壳体可成形为具有与散热块的第一接合部互补地接合的第二接合部。 The housing may be shaped to have a first engaging portion engaging the second complementary engagement of the heat sink block. 根据这种构型,由于壳体上形成有与散热块的外表面上的第一接合部互补的第二接合部,因而散热块与壳体可在接合表面处彼此嵌合,由此可实现散热块与壳体之间更稳定、更紧密并且不松动的固定连接。 According to such a configuration, since the upper casing is formed with a first engaging portion and second engaging portion complementary to the outer surface of the heat dissipation block, and thus the heat dissipation block and the housing may be fitted to each other at the engaging surface, whereby to achieve more stable between the heat sink block and the housing are not more closely and fixedly connected loose.

[0010] 根据本申请的实施方式,第一接合部可包括一个或多个第一凸部和/或第一凹部,第二接合部可形成为具有与所述一个或多个第一凸部和/或第一凹部互补地接合的一个或多个第二凹部和/或第二凸部。 [0010] According to embodiments of the present disclosure, a first engaging portion may include one or a plurality of first convex portions and / or the first concave portion, the second engagement portion may be formed with one or more portions of said first projections one or more second recesses and / or the second convex portion and / or the first portion complementarily engages the recess.

[0011] 根据本申请的实施方式,一个或多个第一凸部和/或第一凹部的延伸方向可不与散热块的延伸方向平行。 [0011] According to embodiments of the present disclosure, the one or more first protrusions and / or the extending direction of the first recess portion may not be parallel to the extending direction of the heat sink block.

[0012] 根据上述构造,由于壳体上形成有与散热块的外表面上的凸部和/或凹部彼此互补地嵌合的凹部和/或凸部,特别地,在散热块的外表面上的凸部和/或凹部的延伸方向不与散热块的延伸方向平行(即垂直于或倾斜于散热块的延伸方向)的情况下,相比于目前常用的通过螺钉、胶粘剂或干涉配合的连接而言,可实现散热块与壳体之间更稳定、更紧密并且不松动的固定连接。 [0012] According to the above configuration, since the convex portion is formed on the outer surface and / or recesses each other recesses and / or projections with a complementary portion of the heat sink block is fitted on the housing, in particular, the outer surface of the heat sink block a case where the convex portion and / or the extending direction of the concave portion is not parallel to the extending direction of the heat sink block (i.e., perpendicular or obliquely to the extending direction of the heat sink block) compared to the currently used by screws, adhesive or interference fit connection , the more stable can be realized between the heat sink block and the housing, and do not loose more closely fixed connection.

[0013] 根据本申请的实施方式,散热块上的第一接合部的第一凸部可包括第一纹路,相应地,壳体上的第二接合部的与第一凸部互补地接合的第二凹部上相应地形成有与所述第一纹路互补地接合的第二纹路。 [0013] According to embodiments of the present disclosure, a first portion of the first engaging protrusion on the heat dissipation block may include a first lines, respectively, with the first projection engaging a complementary second engaging portion on the housing accordingly, the second lines are formed with a complementary engagement with the first lines of the second concave portion.

[0014] 根据本申请的实施方式,第一纹路可包括竖向纹路、水平纹路、倾斜纹路或交叉纹路中的一种或其组合。 [0014] According to embodiments of the present disclosure, the first lines may include vertical lines, horizontal lines, inclined lines or cross lines in one or a combination.

[0015] 根据本申请的实施方式,第一纹路可包括连续的和/或间断的纹路。 [0015] According to embodiments of the present disclosure, the first lines may comprise a continuous and / or intermittent lines.

[0016] 根据上述构造,可进一步增大散热块与壳体之间的嵌合面积,从而实现散热块与壳体之间更稳定、更紧密并且不松动的固定连接。 [0016] According to the above configuration, the fitting may further increase the area between the heat sink block with the housing, thereby achieving a more stable connection between the housing and the heat dissipation block, and does not loose more closely fixed connection.

[0017] 根据本申请的另一方面,提供了一种用于汽车前照灯的LED照明装置,其包括根据本申请的任一前述实施方式的LED单元安装模块和安装在所述LED单元安装模块的散热块的一轴向端部处的LED单元。 [0017] According to another aspect of the present application, there is provided an LED lighting device for a vehicle headlamp, comprising any of the foregoing embodiments of the present disclosure an embodiment of the LED module and the mounting unit mounting the LED unit is mounted in accordance with LED unit at one axial end portion of the heat sink block module. [0018] 根据本申请的实施方式,在LED单元安装模块的散热块的另一轴向端部处可附装有翅片式散热器。 [0018] According to embodiments of the present disclosure, at the other axial end portion of the heat sink block unit mounting an LED module may be attached finned heat sink.

[0019] 根据本申请的再一方面,提供了一种汽车前照灯,其可包括根据本申请前述实施方式的LED照明装置。 [0019] According to another aspect of the present disclosure, there is provided a vehicle headlamp, which may include an LED lighting device according to the foregoing embodiments of the present application.

[0020] 根据本申请的又一方面,提供了制造根据前述任一实施方式的LED单元安装模块的方法。 [0020] According to another aspect of the present application, there is provided a method according to an embodiment of the LED unit manufactured according to the mounting module. 该方法包括如下步骤:步骤A:提供散热块;步骤B:以所述散热块为芯材通过包覆注塑工艺在所述散热块的外部一体地形成壳体。 The method comprises the following steps: Step A: providing a heat sink block; Step B: to the heat dissipation block is formed as a core material in the outer housing of the heat dissipation block integrally covered by an injection molding process.

[0021] 根据本申请的实施方式,步骤A可包括在散热块的外表面上形成第一接合部,相应地,步骤B可包括在壳体上形成与第一接合部互补地接合的第二接合部。 [0021] According to embodiments of the present disclosure, the step A may comprise a first engaging portion formed on the outer surface of the heat sink block, respectively, the step B may include a first engagement portion formed with a complementary engagement in a second housing joint.

[0022] 根据本申请的实施方式,第一接合部可形成为包括一个或多个第一凸部和/或第一凹部,相应地,第二接合部可形成为包括与所述一个或多个第一凸部和/或第一凹部互补地接合的一个或多个第二凹部和/或第二凸部。 [0022] According to embodiments of the present disclosure, a first engaging portion may be formed to include one or a plurality of first convex portions and / or the first concave portion, respectively, the second engagement portion may be formed to include one or more of the a first convex portions and / or one or more second recesses and / or the second protrusion of the first portion complementarily engages the recess.

[0023] 根据本申请的实施方式,一个或多个第一凸部和/或第一凹部可形成为使得其延伸方向不与散热块的延伸方向平行。 [0023] According to embodiments of the present disclosure, the one or more first protrusions and / or the first recess portion may be formed not parallel to the extending direction of the heat sink block such that the extending direction.

[0024] 根据本申请的实施方式,散热块上的第一接合部的第一凸部可形成为具有第一纹路,相应地,壳体上的第二接合部的与第一凸部互补地接合的第二凹部可相应地形成为具有与所述第一纹路互补地接合的第二纹路。 [0024] According to embodiments of the present disclosure, a first portion of the first engaging protrusion on the heat dissipation block may be formed with a first texture, and accordingly, the second engaging portion on the housing and the first convex portion complementarily the second engagement recess portion may be formed as a respective second lines having complementary engagement with the first textured.

[0025] 根据本申请的实施方式,第一纹路可包括竖向纹路、水平纹路、倾斜纹路或交叉纹路中的一种或其组合。 [0025] According to embodiments of the present disclosure, the first lines may include vertical lines, horizontal lines, inclined lines or cross lines in one or a combination.

[0026] 根据本申请的实施方式,第一纹路可包括连续的和/或间断的纹路。 [0026] According to embodiments of the present disclosure, the first lines may comprise a continuous and / or intermittent lines.

[0027] 根据本申请的实施方式,第一纹路可通过滚花工艺而形成在散热块的第一接合部的第一凸部上。 [0027] According to embodiments of the present disclosure, the first lines can be formed on the first protrusion of the first engaging portion of the heat dissipation block knurling.

[0028] 根据本申请的制造LED单元安装模块的方法,由于可在单独的包覆注塑工序中在对壳体进行模制成形的同时将壳体模制到散热块上,因而壳体与散热块可非常紧密地固定在一起并且不松动。 [0028] The method for manufacturing the LED unit mounting module of the present application, since the over-molded in a separate step while the housing will be molded housing molded onto the heat sink block, thereby cooling the housing and block may be very close together and not loose. 另外,可减少构件的制造工序并降低构件的制造公差要求,从而可大大降低制造成本。 Further, the manufacturing process can be reduced to reduce manufacturing and component tolerances member, which can greatly reduce the manufacturing cost. 此外,根据本申请的制造LED单元安装模块的方法还允许在散热块上形成比较复杂的结构,以进一步增强与壳体之间更稳定、更紧密并且不松动的固定连接。 Further, the method of manufacturing the LED unit mounting module of the present disclosure also allows for heat dissipation block is formed on a relatively complicated structure, between the housing and to further enhance a more stable and compact and does not loose fixedly connected.

[0029] 根据本申请的实施方式,步骤B可包括在壳体上形成与应用环境中的连接结构相匹配的连接结构。 [0029] According to embodiments of the present disclosure, B can comprise the step of forming a connection structure and connection structure that matches the application environment in the housing.

附图说明 BRIEF DESCRIPTION

[0030] 根据以下参照附图的详细描述,本申请的前述及另外的特征和特点将变得更加清楚。 [0030] The following detailed description with reference to the accompanying drawings, the present application and additional features and characteristics will become more apparent. 在附图中, In the drawings,

[0031] 图1和图2是分别示出现有的LED单元安装组件10'的立体图及其分解立体图; [0031] Figures 1 and 2 there is mounted an LED unit assembly 10, respectively, illustrating 'a perspective view and an exploded perspective view and a;

[0032] 图3是示出根据本申请的示例性LED单元安装模块10的立体图; [0032] FIG. 3 is a perspective view showing an exemplary LED 10 in the module mounting unit according to the present disclosure;

[0033] 图4是示出图3所示的LED单元安装模块10的分解立体图; [0033] FIG. 4 is an exploded perspective view of the LED mounting module unit 10 is shown in Figure 3;

[0034] 图5是示出图3所示的LED单元安装模块10的沿图3中的AA线剖取的剖视图; [0034] FIG. 5 is a cross-sectional view of the LED unit mounting module shown in FIG. 10 in FIG. 3 AA line shown taken;

[0035] 图6是示出根据本申请的示例性散热块12的立体图; [0035] FIG. 6 is a perspective view showing a heat sink 12 according to an exemplary block of the present disclosure;

[0036] 图7至图10为图6所示散热块12的A区域放大图,分别示出了根据本申请的纹路的示例性表示; [0036] FIG. 7 to FIG. 10 A is a region of the heat sink block 612 shown in FIG enlarged view, respectively, illustrate an exemplary representation of the lines of the present application;

[0037] 图11是根据本申请的示例性LED照明装置I的立体图;以及 [0037] I FIG. 11 is a perspective view of an exemplary LED lighting apparatus according to the present application; and

[0038] 图12是示出图11所示LED照明装置I的分解立体图。 [0038] FIG. 12 is an exploded perspective view of the LED 11 shown in FIG. I shows a lighting device.

[0039] 参考标记列表 [0039] Reference Signs List

[0040] 10' -LED单元安装组件;12'-中央散热块;121'-柱形部;122'-凸缘部;122Γ -安装孔;14'-外部塑料壳;142'-圆筒部;143'-基部;143Γ -安装孔;IO-LED单元安装模块;12_散热块;121-凸柱部;122_凸缘部;123-第一接合部;1231_凸部;1232-凹部;1233-纹路;14_壳体;145-第二接合部;1451-凹部;1452-凸部;1-LED M明装置;20-LED单元;30_翅片散热器。 [0040] 10 '-LED unit mounting assembly; 12' central heat sink block; 121'- cylindrical portion; 122'- flange portion; 122Γ - mounting hole; 14'- external plastic case; 142'- cylindrical portion ; 143'- base; 143Γ - mounting hole; IO-LED unit mounting module; heat sink block 12_; 121- boss portion; 122_ flange portion; 123- a first engaging portion; 1231_ convex portion; 1232- recess ; 1233- lines; housing 14_; 145- second engaging portion; 1451- recess; 1452- convex portions; 1-LED M out means; 20-LED unit; 30_ finned heat sink.

具体实施方式 Detailed ways

[0041] 现在将参照附图对本申请的示例性实施方式进行详细描述。 [0041] Referring now to the drawings exemplary embodiments of the present application will be described in detail. 以下的描述在本质上只是示例性的而非意在限制本申请及其应用或用途。 The following description is merely exemplary in nature and is not intended to limit the present application and its application, or uses.

[0042] 以下将参照图3至图12对根据本申请的LED单元安装模块的示例性实施方式进行描述。 [0042] below with reference to FIG. 3 to FIG. 12 will be described according to an exemplary embodiment of the present application unit mounting LED modules.

[0043] 图3示出了根据本申请的示例性LED单元安装模块10的立体图。 [0043] FIG. 3 shows a perspective view of FIG. 10 according to an exemplary LED unit mounting module according to the present disclosure.

[0044] 参照图3,根据本申请的示例性实施方式的LED单元安装模块10总体包括散热块12和形成于散热块12外部的壳体14,其中,壳体14在其成形过程中与散热块12形成为一体。 [0044] Referring to FIG 3, according to an exemplary embodiment 10 of the overall embodiment of the present disclosure includes a module mounting the LED unit 12 and the heat dissipation block is formed in the outer housing 12 of the heat sink block 14, which, in its housing 14 and the heat forming process block 12 is formed integrally. 需要说明的是,在本申请中,用语“形成为一体”意指壳体14与散热块12在成形阶段即形成为不可分离的整体, 其区别于通过将两个或多个分别成形的部件例如借助于螺钉连接、胶粘剂连接、或者干涉配合等方式组装在一起的结合方式。 Incidentally, in the present application, the term "integrally formed" means that the housing member 14 and the heat block 12 that is formed on the forming stage inseparable whole, which is distinguished by two or more separate shaping for example by means of a screw connection, an adhesive connection, or an interference fit, etc. assembled together in a combination manner. 例如,壳体14可通过注塑模制工艺中的包覆注塑(over mold)工艺而在模制成形的同时一体地模制到散热块12上,从而与散热块12形成为一体。 For example, the housing 14 may be molded simultaneously in molding process by injection molding the over-molded (over mold) is integrally manufactured to the process of the heat dissipation block 12, thereby formed integrally with the heat sink block 12.

[0045] 进一步参照图4和图5,图4是图3所示的LED单元安装模块10的分解立体图,图5是沿图3中的AA线剖取的图3所示的LED单元安装模块10的剖视图。 [0045] Further LED unit mounting module shown in FIG. 3 along line AA of FIG. 3 taken with reference to FIG. 4 and FIG. 5, FIG. 4 is an exploded perspective view of the LED mounting module unit shown in FIG. 10, FIG. 5 is 10 is a sectional view. 需要说明的是,尽管图4中示出了分解开的两个部件,但这仅是为了便于说明,实际上这两个部件在成形阶段是成形为一体的。 Note that, although FIG 4 shows a decomposition of two members apart, this is only for convenience of description, in fact, the two components are integrally formed in molding stage.

[0046] 散热块12由诸如铝或铜的具有良好热传导性的金属材料制成。 [0046] The heat dissipation block 12 is made of a metal such as aluminum or a material having good thermal conductivity of copper. 在图3所示实施方式中,散热块12具有凸柱部121和垂直于凸柱部121的延伸轴线从凸柱部121的一端向外延伸的凸缘部122,凸柱部121的外周面上具有第一接合部123。 In the embodiment shown in FIG. 3, the heat dissipation block 12 having a flange portion and a boss portion 121 extending perpendicularly to the axis of the boss portion 121 extending from one end of the boss portion 121 of the outer periphery of the outer surface 122, 121 of the boss portion having a first engagement portion 123. 需要说明的是,本实施方式设置有凸缘部122以期更为稳固地附装诸如翅片式散热器等进一步的散热装置,本实施方式中所示的凸缘部122的结构并不是必须的,其可根据需要而省略或做其他改型。 Incidentally, the present embodiment is provided with a flange portion 122 in order to more securely attached to a finned heat sinks such as heat sink further, the flange portion 122 of the structure shown in this embodiment is not essential , which may be omitted or made other modifications as desired.

[0047] 壳体14由塑料材料制成。 [0047] The housing 14 made of plastic material. 壳体14在其成形过程中一体地形成于散热块12的外部。 In the housing 14 which is integrally formed during the molding to the outside of the heat sink block 12. 例如,壳体14可通过诸如包覆注塑工艺这样的注塑模制工艺而在其成形过程中与散热块12形成为一体。 For example, the housing 14 may be formed thereon with the heat dissipation block 12 integrally formed during injection molding by this injection molding process, such as coating. 具体地,例如,可在用于成形外壳14的注塑模制工序之前,提供散热块 Before Specifically, for example, it may be used for injection molding step of molding the housing 14, to provide the heat sink block

12。 12. 然后以散热块12为芯材通过包覆注塑工艺在散热块12的外部一体地形成壳体14。 Then cooling block 12 as a core material by coating an injection molding process of the housing 14 is formed integrally on the outside of the heat sink block 12. 如此,可在一个包覆注塑工序中,使壳体14在其成形过程中一体地成形于散热块12的外部,从而与散热块12形成为不可分离的整体。 Thus, a coating may be injection molding step, in which the casing 14 is integrally formed during the molding to the outside of the heat sink block 12, to thereby form an inseparable whole the heat dissipation block 12. 相应地,壳体14上形成有与散热块12上的第一接合部123互补地接合的第二接合部145。 Accordingly, the heat dissipation block is formed on the first engaging portion 12 engaging the second complementary engagement 145,123 on the housing 14. 如图4和图5所示例性示出的,在上述成形过程中还一并在壳体14上形成有与应用环境中的连接结构相匹配的连接结构(未标号)。 4 and 5 exemplarily shown, is also formed together with a connection structure that matches the application environment of the connecting structure (not numbered) in the housing 14 in the above-described forming process.

[0048] 根据本申请的实施方式,散热块12上的第一接合部123包括环绕外周面的两个凸部1231和位于这两个凸部1231之间的凹部1232,相应地,壳体14上的第二接合部145形成有与第一接合部123的两个凸部1231相对应的两个凹部1451和与第一接合部123的凹部1232相对应的凸部1452。 [0048] According to embodiments of the present disclosure, the heat sink block 123 on the first engagement portion 12 includes two convex portions around the outer peripheral surface 1231 and the recess 1232 is located between the two convex portions 1231, respectively, the housing 14 the second joint portion 145 is formed with two concave portions 1232 and the recesses 1231 of the first engaging two protrusions 123 corresponding to the engaging portion 1451 and a second protrusion 123 corresponding to portion 1452. 如图5所示,形成为一体的散热块12和壳体14相互嵌合在一起而形成一体式的LED单元安装模块10。 5, integrally formed cooling block 12 and the housing 14 are fitted together to form an integral unit of the LED module 10 is mounted.

[0049]另外,尽管图示实施方式中示出散热块上的第一接合部包括环绕外周面的两个凸部和位于两个凸部之间的一个凹部,但是,本领域技术人员可以理解,凹部和凸部的设置位置、数量、方向、深度、宽度等可有多种变型,只要适于在散热块以及与散热块形成为一体的壳体之间形成相互间稳固结合即可,例如,散热块上的第一接合部也可包括更多个横向的、竖向的或倾斜的凹部,和/或者可包括一个或更多个横向的、竖向的或倾斜的凸部等。 [0049] Further, although the illustrated embodiment shows an engaging portion between the first recess portion on the heat dissipation block comprises two convex portions and surrounding an outer circumferential surface of the two convex portions is located, however, be appreciated that those skilled in the art , concave and convex portions provided location, number, direction, depth, width, etc. there may be many variations to form a solid bond between each other as long as one is adapted to be formed between the housing and the heat dissipation block and the heat dissipation block, e.g. a first engaging portion on the heat sink block may also comprise more horizontal, vertical or inclined concave portion and / or the inclination or the like of the convex portion may comprise one or more horizontal, vertical. 优选地,在散热块的外表面上形成的凸部和/或凹部的延伸方向不与散热块的延伸方向平行(即,垂直于或倾斜于散热块的延伸方向)。 Preferably, the outer surface of the convex portion formed on the heat sink block and / or the extending direction of the concave portion is not parallel to the extending direction of the heat sink block (i.e., perpendicular or obliquely to the extending direction of the heat sink block). 相应地,壳体上的第二接合部也可形成有对应的多种变型。 Accordingly, the second engaging portion on the housing may also be formed with a corresponding plurality of variants. 所有这样的变型和组合都属于本申请的保护范围内。 Within the scope all such variations and combinations are part of this disclosure.

[0050] 根据本申请的进一步的实施方式,如图6所示,散热块12的第一接合部123的凸部1231的外周面可以是非光滑的,即形成有纹路1233,从而使壳体14在散热块12上形成得更为紧密和牢固而不松动。 [0050] According to a further embodiment of the present application, as shown, the outer circumferential surface of the heat sink block 12 a first engagement protrusion 123 1231 6 may be non-smooth, i.e., 1233 lines are formed, so that the housing 14 It is formed more tightly and securely without looseness in the heat sink block 12. 纹路1233例如可通过滚花等机加工工艺形成于凸部1231的外周面上。 For example, lines 1233 formed on the outer peripheral surface of the convex portion 1231 and the like may be prepared by knurling machining process. 相应地,在成形在散热块12外部上的壳体14的第二接合部145上与凸部1231互补地接合的凹部1451上相应地形成有与纹路1233互补地接合的纹路(未示出)。 Accordingly, the second engaging portion 145 formed on the exterior of the heat sink block 12 of the housing 14 and the upper concave portion 1451 engages a complementary projection portion 1231 engaged with a correspondingly formed complementary lines 1233 and the lines (not shown) .

[0051] 如图7至图10所示,纹路1233可包括竖向纹路(见图7)、水平纹路(见图8)、倾斜纹路(见图9)和交叉纹路(见图10)中的一种或其组合。 [0051] As shown in FIG. 7 to FIG. 10, lines 1233 may include vertical lines (see FIG. 7), horizontal lines (see FIG. 8), oblique lines (see FIG. 9) and the cross lines (see FIG. 10) or a combination thereof. 需要说明的是,图示实施方式仅用于说明的目的而并非意在以任何方式限制本申请的范围。 It should be noted that the illustrated embodiments are for purposes of illustration and are not intended to limit the disclosure in any way. 因此,本领域技术人员可以理解,可根据需要选择适当的纹路的间距、纹路的深度、纹路的倾斜角度和/或交叉角度。 Thus, those skilled in the art will appreciate, according to the inclination angle of the lines need to select the appropriate pitch, the depth of the lines, the lines and / or crossing angle. 此外,纹路1233可根据需要选择为包括连续的和/或间断的纹路(未示出)。 Furthermore, lines 1233 may be selected according to necessity include continuous and / or intermittent lines (not shown). 所有这样的改变和组合都属于本申请的保护范围内。 Within the scope of all such changes and combinations are part of this disclosure.

[0052] 参照图11和图12,图11和图12示出了一种根据本申请的用于汽车前照灯的示例性LED照明装置1,其包括LED单元安装模块10和安装在该LED单元安装模块的散热块的一轴向端部处的LED单元。 [0052] Referring to FIG. 11 and FIG. 12, FIG. 11 and FIG. 12 illustrates an exemplary LED lighting apparatus according to the vehicle headlamp 1 of the present application, which includes an LED unit of the LED module 10 and mounted on the mounting means mounting the heat sink block module of a LED unit at the axial end portions. 进一步地,在LED单元安装模块10的散热块的另一轴向端部可附装有翅片式散热器30以增强散热效果。 Further, the LED unit is mounted in the other axial end portion of the module the heat slug may be attached with a finned heat sink 10 to enhance the heat dissipation effect 30. 组装好的LED照明装置通过壳体上形成的连接结构与应用环境(例如,汽车前照灯)上的连接结构的接合而实现LED照明装置在应用环境中的安装。 Assembled connection structure application environment (e.g., automobile headlamps) engaging the connecting structure of the LED lighting device is formed on the housing is achieved by mounting the LED lighting device in the application environment. 需说明的是,本文中所提及的“LED单元”不专指LED器件本身、还包括诸如LED器件与印刷电路板和/或基板的组件等各种含有LED器件的组件。 It is noted that, herein referred "LED element" not exclusively the LED device itself, further comprising a component containing various LED devices, such as LED devices and printed circuit boards and / or other components of the substrate.

[0053] 以上参照附图并通过实施方式对本申请进行了说明,但是本申请并不局限于上述实施方式。 [0053] The above reference to the drawings of the present application has been described by way of embodiments, but the present application is not limited to the above embodiments. 本领域技术人员可以理解,在不脱离本申请技术思想以及所附权利要求的范围的情况下可以进行各种修改和变型,这些修改和变型同样包含在本申请的保护范围内。 Those skilled in the art will appreciate, without departing from the scope of the technical idea of ​​the present application and the appended claims various modifications and variations, modifications and variations likewise be included within the scope of the present disclosure.

Claims (20)

1.一种LED单元安装模块(10),用于实现LED单元在应用环境中的安装,所述LED单元安装模块包括散热块(12)和位于散热块外部的壳体(14),LED单元附装于所述散热块上,所述壳体上形成有与所述应用环境中的连接结构相匹配的连接结构,其特征在于,所述壳体在该壳体的成形过程中与所述散热块形成为一体。 An LED unit mounting module (10) for enabling the LED unit is mounted in the application environment, the LED unit mounting module includes a heat block (12) and the heat sink block positioned outside of the housing (14), the LED unit attached to said heat sink block, connected to the structure and connection structure that matches the application environment is formed on the housing, wherein the housing during shaping of the housing with the a heat dissipation block integrally formed.
2.根据权利要求1所述的LED单元安装模块,其中,所述壳体通过包覆注塑与所述散热块形成为一体。 2. The LED module mounting unit according to claim 1, wherein said housing is formed by extrusion-coated with the heat dissipation block integrally.
3.根据权利要求1或2所述的LED单元安装模块,其中,所述散热块的外表面上具有第一接合部(123),所述壳体成形为具有与所述第一接合部互补地接合的第二接合部(145)。 3. The LED unit mounting module of claim 1 or claim 2, wherein an outer surface of the heat sink block has a first engaging portion (123), said housing having a shaped complementary to the first engagement a second engaging portion (145) engaged.
4.根据权利要求3所述的LED单元安装模块,其中,所述第一接合部(123)包括一个或多个第一凸部(1231)和/或第一凹部(1232),所述第二接合部(145)形成为具有与所述一个或多个第一凸部和/或第一凹部互补地接合的一个或多个第二凹部(1451)和/或第二凸部(1452)。 The LED module mounting unit according to claim 3, wherein said first engaging portion of said first (123) comprises one or more first protruding portions (1231) and / or the first concave portion (1232), two joint (145) is formed with one or more of the first convex portions and / or one or more second recesses (1451) complementary to the first engaging recess portion and / or the second convex portion (1452) .
5.根据权利要求4所述的LED单元安装模块,其中,所述一个或多个第一凸部和/或第一凹部的延伸方向不与所述散热块的延伸方向平行。 5. The LED module mounting unit according to claim 4, wherein said one or more first protrusions and / or the extending direction of the first recess without the extending direction parallel to the heat sink block.
6.根据权利要求4所述的LED单元安装模块,其中,所述第一接合部的所述第一凸部包括第一纹路(1233),所述第二接合部的与所述第一凸部互补地接合的第二凹部上相应地形成有与所述第一纹路互补地接合的第二纹路。 The LED module mounting unit according to claim 4, wherein said first engaging portion comprises a first portion of the first convex lines (1233), said second engaging portion with the first convex accordingly, the second lines are formed with a complementary engagement with the first lines of the second concave portion complementary engaging portion.
7.根据权利要求6所述的LED单元安装模块,其中,所述第一纹路包括竖向纹路、水平纹路、倾斜纹路和交叉纹路中的一种或其组合。 The LED module mounting unit according to claim 6, wherein said texture comprises a first vertical lines, horizontal lines, and tilted lines in crossing lines or a combination thereof.
8.根据权利要求6所述的LED单元安装模块,其中,所述第一纹路包括连续的和/或间断的纹路。 The LED module mounting unit according to claim 6, wherein the first lines comprises a continuous and / or intermittent lines.
9.一种用于汽车前照灯的LED照明装置,其包括如前述权利要求中的任一项所述的LED单元安装模块(10)和安装在所述LED单元安装模块的所述散热块(12)的一轴向端部处的LED单元。 A vehicle headlamp LED lighting device, comprising any of the preceding claims in one of the LED unit mounting module (10) and the LED unit is mounted on the heat sink block mounted modules (12) a LED unit at the axial end portions.
10.如权利要求9所述的LED照明装置,其特征在于,在所述LED单元安装模块(10)的所述散热块(12)的另一轴向端部附装有翅片式散热器(30)。 10. The LED lighting device according to claim 9, characterized in that the other axial end portion of said heat slug (12) in the LED unit mounting module (10) is attached finned heat sink (30).
11.一种汽车前照灯,包括如权利要求9或10所述的LED照明装置。 A vehicle headlamp, comprising a LED lighting device as claimed in claim 9 or claim 10.
12.—种制造如权利要求1至8中的任一项所述的LED单元安装模块(10)的方法,包括如下步骤: 步骤A:提供散热块(12), 步骤B:以所述散热块为芯材通过包覆注塑工艺在所述散热块的外部一体地形成壳体(14)。 12.- manufacture any kinds of claims 1 to 8, the LED unit mounting module (10), comprising the following steps: Step A: providing a heat sink block (12), Step B: to the heat block forming the core housing (14) in an injection molding process by coating the outside of the heat dissipation block integrally.
13.根据权利要求12所述的制造LED单元安装模块的方法,其中,所述步骤A包括在散热块的外表面上形成第一接合部(123),所述步骤B包括在所述壳体上形成与所述第一接合部互补地接合的第二接合部(145)。 13. A method for manufacturing an LED module mounting unit according to claim 12, wherein the step A comprises forming a first joint (123), said step B is included in the housing of the outer surface of the heat sink block a second engaging portion formed on the (145) complementary to the first engaging portion engaged.
14.根据权利要求13所述的制造LED单元安装模块的方法,其中,所述第一接合部形成为包括一个或多个第一凸部(1231)和/或第一凹部(1232),所述第二接合部形成为包括与所述一个或多个第一凸部和/或第一凹部互补地接合的一个或多个第二凹部(1451)和/或第二凸部(1452)。 14. The method of manufacturing an LED module mounting unit according to claim 13, wherein said first engaging portion is formed to include one or more first protrusions (1231) and / or the first concave portion (1232), the said second engagement portion formed to include one or more of the first convex portions and / or the first concave portion complementarily engages the one or more second recesses (1451) and / or the second convex portion (1452).
15.根据权利要求14所述的制造LED单元安装模块的方法,其中,所述一个或多个第一凸部和/或第一凹部形成为使得其延伸方向不与所述散热块的延伸方向平行。 15. A method for manufacturing an LED module mounting unit according to claim 14, wherein said one or more first protrusions and / or the first concave portion is formed such that it does not extend direction of the extending direction of the heat dissipation block parallel.
16.根据权利要求14所述的制造LED单元安装模块的方法,其中,所述第一接合部的所述第一凸部形成为具有第一纹路(1233),所述第二接合部的与所述第一凸部互补地接合的第二凹部(1451)相应地形成为具有与所述第一纹路互补地接合的第二纹路。 16. The method of manufacturing an LED module mounting unit according to claim 14, wherein the first protrusion of the first engaging portion is formed to have a first texture (1233), and the second joint a second concave portion (1451) complementary to the first convex portion engaging a respective second lines formed as having engaged with the first complementary textured.
17.根据权利要求16所述的制造LED单元安装模块的方法,其中,所述第一纹路包括竖向纹路、水平纹路、倾斜纹路和交叉纹路中的一种或其组合。 17. A method for manufacturing an LED module mounting unit according to claim 16, wherein said texture comprises a first vertical lines, horizontal lines, and tilted lines in crossing lines or a combination thereof.
18.根据权利要求16所述的制造LED单元安装模块的方法,其中,所述第一纹路包括连续的和/或间断的纹路。 18. A method for manufacturing an LED module mounting unit according to claim 16, wherein the first lines comprises a continuous and / or intermittent lines.
19.根据权利要求16所述的制造LED单元安装模块的方法,其中,所述第一纹路通过滚花工艺而形成在所述第一凸部上。 19. A method for manufacturing an LED module mounting unit according to claim 16, wherein the first texture formed on the first projecting portion by a knurling process.
20.根据权利要求12至19中的任一项所述的制造LED单元安装模块的方法,其中,所述步骤B包括在所述壳体上形成与应用环境中的连接结构相匹配的连接结构。 20. A method for manufacturing an LED module mounting unit 12 according to any of claims 19, wherein said step B includes a connection structure formed on said housing structure and application environment matches .
CN2011104212212A 2011-12-15 2011-12-15 Light-emitting diode (LED) unit installing module and manufacturing method thereof and LED lighting device and automobile headlamp CN103162207A (en)

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