CN106662312A - 基于发光二极管的日行灯 - Google Patents

基于发光二极管的日行灯 Download PDF

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CN106662312A
CN106662312A CN201580047182.0A CN201580047182A CN106662312A CN 106662312 A CN106662312 A CN 106662312A CN 201580047182 A CN201580047182 A CN 201580047182A CN 106662312 A CN106662312 A CN 106662312A
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drl
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理查德·雅克·西奥多·弗雷森
西瓦·艾萨克姆瑟·苏伯默尼安
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Abstract

包含载体的基于发光二极管(LED)的日行灯(DRL)，所述载体包含含有聚对苯二甲酸乙二醇酯和玻璃纤维的聚合物组合物，所述载体的表面包含用于安装一个或多个LED的导体轨道。

Description

基于发光二极管的日行灯
日行灯(DRL)(也称为昼行灯)是公路机动车或自行车前面的汽车闪电装置和自行车闪电装置，最终在车辆向前移动时自动打开，从而发射白色、黄色或琥珀色光以增加在白天条件下车辆的能见度。
日行灯在冬季持续黑暗的斯堪的纳维亚国家首先授权并感知到安全益处。
日行灯的功能最初是通过以最高强度或降低的强度操作近光前照灯或甚至雾灯，通过以降低的强度操作远光前照灯，或者通过稳定地燃烧前转向信号等来实现的。
欧盟指令2008/89/EC要求在2011年2月7日或之后在欧盟批准的所有乘用车和I型小型货车配备日行灯。该命令于2012年8月扩展到卡车和公共汽车。不再允许提供双重功能的DLR，例如将前照灯或前转向信号灯灯或雾灯作为DRL操作，并且欧盟指令要求功能特定的日行灯符合ECE规章87，并根据ECE规章48被安装到车辆上以符合R87发射400-1200坎德拉的白光。在世界上的其它国家，DRL也是强制性的。
DLR能量消耗因实施情况而变化很大。迄今为止，基于发光二极管(LED)的DRL系统获得了最低能量消耗。因此，这种系统得到欧盟的支持，并且被认为在充分提高安全性的同时几乎不增加燃料消耗。通常使用几个LED的光束，所述光束有时构建在机动车辆的前照灯中。
市场上提供的现有技术中的基于LED的DRL基于聚碳酸酯载体和聚酰亚胺膜，其包括在膜上的导体轨道的结构。用金属夹将该膜安装在载体上。将LED焊接在膜的导体轨道上。膜和载体之间存在间隙以确保载体不被LED加热。
已知的基于LED的DRL的问题是其昂贵，这是因为它很难生产。另一个问题是，如果仅一个组件失效，则整个组装体在生产后必须被拒绝。另一个问题是，已知的基于LED的DRL在使用期间显示出大量故障。
US 2013/0193452中公开了一种LED系统，其具有符合三维载体(也称为散热器)的弯曲的层状结构。弯曲的层状结构包括类似的聚酰亚胺膜，其包含在膜上的导体轨道的结构。LED被焊接在膜的导体轨道上。三维载体是导热材料(如铝)或导热聚合物。该系统可应用于各种类型的灯，但并未提及DLR。
由US 2013/0193452已知的基于LED的DRL的问题在于，它仍然是昂贵的，这是因为它很难生产。另一个问题是，如果仅一个组件失效，则整个组装体在生产后必须被拒绝。
本发明的目标是提供基于LED的DRL，其具有简单得多的结构，以使得其不显示上述问题。
令人惊讶的是，通过提供包含载体的基于LED的DRL已实现了该目标，所述载体包含含有聚对苯二甲酸乙二醇酯、玻璃纤维和激光定向结构(LDS)添加剂的聚合物组合物，所述导体轨道是通过LDS工艺和随后的镀金属、优选地镀铜-镍-金来提供的。
通过这种方式，已经获得了具有非常简单的结构的DRL，载体是一个整合的单部件。DRL易于生产；由于高LED精度，生产后的拒绝非常低；并且DRL的故障也非常低。此外，载体显示出低脱气，例如当DRL整合在前照灯中时，这是非常重要的。令人惊讶的是，尽管组合物中存在玻璃纤维和LDS添加剂，但是组合物具有非常好的流动性能。最后，组合物的螺钉耐性(screw resisitance)高。这使得载体能够通过标准螺钉固定而安装到汽车上，同时提供仍然足够的汽车/道路振动模式耐性。
根据本发明的DRL可包含5-30个LED。优选地，DRL包含15-25个LED。优选地，LED在12伏特下每个LED消耗少于2瓦特、更优选地少于1瓦特、甚至更优选地少于0.75瓦特。这确保了足够的能见度、低能量消耗和载体的适度加热。
聚对苯二甲酸乙二醇酯聚合物是包含对苯二甲酸和乙二醇作为单体单元的聚酯。聚对苯二甲酸乙二醇酯还可以含有少量其它二酸(例如间苯二甲酸)或少量其它二醇(例如二乙二醇)作为共聚单体。优选地，载体的组合物至少包含聚对苯二甲酸乙二醇酯均聚物。聚对苯二甲酸乙二醇酯均聚物在本文中被理解为含有少于5mol％的不同于对苯二甲酸和乙二醇那些单体单元的单体单元。这种均聚物的优点是更高的熔点和更好的结晶行为。更优选地，聚对苯二甲酸乙二醇酯均聚物含有少于4mol％、甚至更优选少于3mol％、最优选少于2mol％的不同于对苯二甲酸和乙二醇那些单体单元的单体单元。优选地，组合物中至少50重量(wt)％、更优选地至少90重量％、最优选地至少95重量％的聚对苯二甲酸乙二醇酯是均聚物。
聚对苯二甲酸乙二醇酯的相对溶液粘度(RSV，在25℃下对1克聚合物在125克7/10(m/m)三氯苯酚/苯酚混合物中的溶液进行测定；基于ISO1628-5的方法)可以为1.50-2.00、优选地1.60-1.85、最优选地1.65-1.80。通常，较高的RSV导致组合物的强度和韧性得到改善，而较低的RSV促进熔体流动和结晶速度。在本发明的RSV范围时，达到了最佳性能，而不需要添加冲击改性剂或流动促进剂，这有利于甚至进一步延长RF外壳的使用期限。为了达到这些RSV值，聚对苯二甲酸乙二醇酯可已经以固态后缩合，例如通过在惰性气氛中使颗粒形式的组合物暴露于比其熔点低最多约10℃的高温持续数小时来实现。这种固态后缩合的另一个优点是：存在于组合物中并且可能影响组合物的加工性能或其模制部件的性质的任何挥发物基本上被除去。
聚合物组合物优选地含有成核剂以增强聚对苯二甲酸乙二醇酯的结晶。可以使用任何已知的成核剂作为成核剂。优选使用无机添加剂(例如微滑石)或金属羧酸盐，特别是碱金属羧酸盐(例如苯甲酸钠)。更优选地，苯甲酸钠的使用量为约0.05-0.5质量％(基于聚对苯二甲酸乙二醇酯)。
适用于聚合物组合物中的玻璃纤维可具有5-20μm、优选地8-15μm、最优选地9-11μm的纤维直径，用于机械性能和加工性能的最佳平衡。优选地，玻璃纤维的表面上具有胶料，所述胶料与聚对苯二甲酸乙二醇酯相容并且含有环氧官能化合物或氨基官能化合物。优选地，胶料含有环氧官能化合物。其优点是：在聚对苯二甲酸乙二醇酯中良好的分散性和改进的聚合物组合物的长期机械性能，特别是疲劳性能。
聚合物组合物可以含有10-60重量％的玻璃纤维。优选地，聚合物组合物含有30-50重量％、最优选地35-45重量％的玻璃纤维。
组合物优选地含有导热填料，以确保载体的良好热传导，以传送LED所产生的热。优选地，导热材料的热导率λ(W/m.K)比聚合物组合物(但不含热导材料)的热导率高优选地至少5倍、更优选地至少25倍、甚至更优选地至少100倍。
导热填料包括例如铝、氧化铝、铜、镁、氧化镁、黄铜、氮化硅、氮化铝、氮化硼、氧化锌、石墨(优选地膨胀石墨)、PITCH基碳纤维等填料。这种导热材料的混合物也是合适的。导热填料的形式可以为粒状粉末、颗粒、晶须、短纤维、薄片、小片、米、线或球状形状或任何其它合适的形式。相对于聚合物组合物的总量，导热填料的存在量为优选地1-10重量％、更优选地2-7重量％。
最优选地，导热材料是膨胀石墨，因为这是非常有效的。
组合物适当地包含周期系的d族或f族中的金属的无机金属化合物作为LDS添加剂。优选地，无机金属化合物是金属氧化物。优选氧化铜。最优选地，使用铜和镍化合物的混合物作为LDS添加剂。可通过以下方式产生导体轨迹：用二极管泵浦Nd：Yag激光辐照包含LDS添加剂的载体以释放金属核用于进一步的金属化处理。在另一步骤中，可将载体引入化学金属化浴中，以施加导体轨迹。
载体的组合物还可包含0-20质量％的其它纤维或微粒状矿物填料。优选使用填料颗粒，例如滑石或高岭土，这是因为它们有助于组合物的刚度，而不会不期望地增强组合物的性质的各向异性。
根据本发明的方法中使用的聚合物组合物还可以包含常用的添加剂，如稳定剂、抗氧化剂、着色剂、加工助剂(如脱模剂)、粘度改性剂(如扩链剂)、冲击改性等等。
优选地，聚合物组合物含有少于5重量％、更优选地少于3重量％、最优选地少于1重量％的常用添加剂。

Claims (4)

1.包含载体的基于发光二极管(LED)的日行灯(DRL)，所述载体包含含有聚对苯二甲酸乙二醇酯、玻璃纤维和激光定向结构(LDS)添加剂的聚合物组合物，所述导体轨道是通过LDS工艺和随后的金属电镀提供的。
2.根据权利要求1所述的基于LED的DRL，其中所述聚合物组合物包含10-60重量％的玻璃纤维。
3.根据权利要求1所述的基于LED的DRL，其中所述聚合物组合物包含30-50重量％的玻璃纤维。
4.基于LED的DRL，其中所述聚合物组合物包含35-45重量％的玻璃纤维。
CN201580047182.0A 2014-09-05 2015-07-20 基于发光二极管的日行灯 Pending CN106662312A (zh)

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