US20140063830A1 - Lighting apparatus for vehicle and manufacturing method for the same - Google Patents

Lighting apparatus for vehicle and manufacturing method for the same Download PDF

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Publication number
US20140063830A1
US20140063830A1 US14/015,590 US201314015590A US2014063830A1 US 20140063830 A1 US20140063830 A1 US 20140063830A1 US 201314015590 A US201314015590 A US 201314015590A US 2014063830 A1 US2014063830 A1 US 2014063830A1
Authority
US
United States
Prior art keywords
lighting
lighting source
circuit board
printed circuit
cover
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US14/015,590
Other languages
English (en)
Inventor
Jaehong Kim
Young Sub Oh
Bock Cheol Lee
Dong Gon Kang
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hyundai Motor Co
Hyundai Mobis Co Ltd
Kia Corp
Original Assignee
Hyundai Motor Co
Kia Motors Corp
Hyundai Mobis Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hyundai Motor Co, Kia Motors Corp, Hyundai Mobis Co Ltd filed Critical Hyundai Motor Co
Assigned to HYUNDAI MOTOR COMPANY, KIA MOTORS CORPORATION, HYUNDAI MOBIS CO., LTD. reassignment HYUNDAI MOTOR COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KANG, DONG GON, KIM, JAEHONG, LEE, BOCK CHEOL, OH, YOUNG SUB
Publication of US20140063830A1 publication Critical patent/US20140063830A1/en
Priority to US14/923,143 priority Critical patent/US9992877B2/en
Abandoned legal-status Critical Current

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Classifications

    • F21S48/00—
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V3/00—Globes; Bowls; Cover glasses
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/22—Secondary treatment of printed circuits
    • H05K3/28—Applying non-metallic protective coatings
    • H05K3/284—Applying non-metallic protective coatings for encapsulating mounted components
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S43/00—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights
    • F21S43/10—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by the light source
    • F21S43/13—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by the light source characterised by the type of light source
    • F21S43/14—Light emitting diodes [LED]
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S43/00—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights
    • F21S43/10—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by the light source
    • F21S43/19—Attachment of light sources or lamp holders
    • F21S43/195—Details of lamp holders, terminals or connectors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S43/00—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights
    • F21S43/20—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by refractors, transparent cover plates, light guides or filters
    • F21S43/26—Refractors, transparent cover plates, light guides or filters not provided in groups F21S43/235 - F21S43/255
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
    • H05K3/303—Surface mounted components, e.g. affixing before soldering, aligning means, spacing means
    • H05K3/305—Affixing by adhesive
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/13—Moulding and encapsulation; Deposition techniques; Protective layers
    • H05K2203/1305—Moulding and encapsulation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
    • Y10T29/4913—Assembling to base an electrical component, e.g., capacitor, etc.

Definitions

  • the present invention relates to a lighting apparatus for a vehicle and a manufacturing method for the same. More particularly, the present invention relates to a flexible lighting apparatus for a vehicle and a manufacturing method for the same.
  • a vehicle is provided with various lighting apparatus to a front and rear side of the vehicle for offering safety and driving convenience and the lighting apparatus is a headlight, a tailing, a turn signal lamp and so on.
  • the lighting apparatus includes at least one lighting source for emitting light, and recently an LED (Light Emitting Diode), having enhanced luminance efficiency, is widely used as the lighting source.
  • LED Light Emitting Diode
  • a lighting apparatus including an LED as lighting source has been developed.
  • the lighting apparatus having the LED as the lighting source basically includes a PCB (Printed Circuit Board) for mounting the LED, a heat sink mounted to the PCB for radiating heat of the LED, and a lens for distributing the light of the LED to the outside.
  • PCB Print Circuit Board
  • the lighting apparatus having the LED as the lighting source may further include a reflector for reflecting the light emitted from the LED, a shield for shutting out a part of the light emitting from the LED or a part of the light reflected by the reflector, a light guide for total reflection of the light emitted from the LED.
  • the LED is disposed outside of the light guide and the emitted light from the LED is laminated into the light guide. So, when the light emitted from the LED passes into the light guide though air, optical loss or optical attenuation may happen so that luminance efficiency may be deteriorated.
  • DRL Daytime Running Lighting
  • a general lighting apparatus is formed with hardened elements and design of a vehicle is various and thus various design of a lighting apparatus are required for responding the various vehicle design.
  • Various aspects of the present invention are directed to providing a lighting apparatus for a vehicle and a manufacturing method for the same having advantages of flexibility responding to a mounting portion of a vehicle for the lighting apparatus.
  • a lighting apparatus for a vehicle may include a flexible printed circuit board of which at least one lighting source is mounted on an upper surface of the flexible printed circuit board, and a cover which is made of flexible material, and connected on the printed circuit board for the at least one lighting source to be disposed within the cover, wherein the cover distributes a light emitted from the at least one lighting source to an upper direction of the cover.
  • the lighting apparatus further may include a reflective portion adhering to the upper surface of the printed circuit board between the printed circuit board and the cover for reflecting the light emitted from the at least one lighting source to distribute the light through the cover.
  • the cover is made of transparent material.
  • the cover is formed by UV (Ultraviolet) resin.
  • a lighting surface is formed to a side of the at least one lighting source.
  • the at least one lighting source is plural, and the plurality of lighting sources may include a first lighting source and a second lighting source of which each lighting surface faces each other.
  • the at least one lighting source is plural, wherein the plurality of lighting sources may include a first lighting source and a second lighting source which are disposed apart from each other and of which each lighting surface faces the same direction, and a third lighting source of which a lighting surface faces toward between the first lighting source and the second lighting source, wherein the first lighting source, the third lighting source and the second lighting sources are arranged alternatively along the flexible printed circuit board.
  • the at least one lighting source is a LED (Light Emitting Diode).
  • the cover closely contacts to the printed circuit board.
  • a manufacturing method for a lighting apparatus for a vehicle may include mounting at least one lighting source to a flexible printed circuit board of which a reflective portion is adhesive to an upper surface of the flexible printed circuit board, fixing the printed circuit board to a suction table, holding a boundary frame on the suction table for the printed circuit board inserted therein, supplying melted resin within the boundary frame for the at least one lighting source to be immersed within the resin, and hardening the resin.
  • the suction table is connected to a vacuum device and an inside pressure of the suction table is selectively lowered by operation of the vacuum device, wherein a suction hole is formed to the suction table, and wherein the printed circuit board is fixed to the suction table through the suction hole by a negative pressure within the suction table.
  • the manufacturing method further may include vibrating the suction table for leveling of the melted resin after immersing the at least one lighting source within the resin.
  • the cover is made of transparent material.
  • the cover is formed by UV (Ultraviolet) resin.
  • the hardening the resin is executed by the lighting apparatus passing through a UV hardening device.
  • a lighting surface is formed to a side of the at least one lighting source.
  • the at least one lighting source is plural, wherein the plurality of lighting sources may include a first lighting source and a second lighting source of which each lighting surface faces each other.
  • the at least one lighting source is plural, wherein the plurality of lighting sources may include a first lighting source and a second lighting source which are disposed apart from each other and of which each lighting surface faces the same direction, a third lighting source of which a lighting surface faces toward between the first lighting source and the second lighting source, and wherein the first lighting source, the third lighting source and the second lighting sources are arranged alternatively along the flexible printed circuit board.
  • the at least one lighting source is a LED (Light Emitting Diode).
  • the lighting apparatus may be easily mounted to a vehicle without regard to shape of a mounting portion to match the design of a vehicle with flexibility.
  • FPCB Flexible Printed Circuit Board
  • the lighting apparatus For the lighting source is disposed within the cover, thus luminance efficiency may be enhanced comparing a general lighting apparatus which is disposed outside of a cover.
  • the lighting apparatus according to an exemplary embodiment of the present invention may be widely used as various lighting apparatus as a stop lamp, a turn signal lamp and so on.
  • FIG. 1 is a drawing showing a lighting apparatus for a vehicle according to a first exemplary embodiment of the present invention.
  • FIG. 2 is a drawing showing a lighting apparatus for a vehicle according to a various exemplary embodiments of the present invention.
  • FIG. 3 and FIG. 4 are drawings showing a manufacturing method for a lighting apparatus according to an exemplary embodiment of the present invention.
  • FIG. 5 is a flowchart of a manufacturing method for a lighting apparatus according to an exemplary embodiment of the present invention.
  • FIG. 1 is a drawing showing a lighting apparatus for a vehicle according to a first exemplary embodiment of the present invention.
  • a lighting apparatus 100 includes a flexible printed circuit board (FPCB) 10 and a cover 20 made of flexible material and disposed on the printed circuit board 10 .
  • FPCB flexible printed circuit board
  • the lighting source 12 may be an LED (Light Emitting Diode) and a lighting surface 11 is formed to a side of the lighting source 12 .
  • two lighting source 12 a and 12 b as the first lighting source 12 a and the second lighting source 12 b as a set are disposed on the upper surface of the printed circuit board 10 of which each lighting surface 11 faces each other.
  • 3 sets of the first lighting source 12 a and the second lighting source 12 b are disposed facing of which each lighting surface 11 faces each other, but is not limited thereto.
  • At least one lighting source 12 will be denoted as the lighting source 12 for convenience description.
  • a reflective portion 15 for reflecting the light emitted from lighting source 12 is disposed on the upper surface of the printed circuit board 10 .
  • Patterns for reflecting emitted from lighting source 12 may be printed on the upper surface of the reflective portion 15 , and the reflective portion 15 may be thin film and adhered to the upper surface of the printed circuit board 10 .
  • the reflective portion 15 is adhered to the upper surface of the printed circuit board 10 , a shield element for shutting out light passing to the other surface of the reflective portion 15 may not be required.
  • the lighting source 12 is electrically connected to the printed circuit board 10 through the reflective portion 15 and protrudes from the reflective portion 15 .
  • the intensity of radiation reflected by the reflective portion 15 may sufficiently be secured.
  • the lighting source 12 is immersed within the cover 20 and disposed within the cover 20 . That is, the cover 20 closely contacts the reflective portion 15 and is disposed on the printed circuit board 10 , and distributes the light reflected by the reflective portion 15 through the upper portion thereof.
  • the cover 20 is made of transparent material for distributing the light reflected by the reflective portion 15 .
  • the cover 20 may be formed by resin, for example plastic material, is supplied on the reflective portion 15 of the printed circuit board 10 as melted state, and is hardened. And thus the lighting source 12 is immersed within the cover 20 and the cover 20 is connected with the printed circuit board 10 .
  • the lighting source 12 is disposed within the cover 20 not outside of the cover 20 and the light emitted from lighting source 12 does not pass through air, thus the light may be prevented from being disappeared due to total reflection and also luminance efficiency may be improved.
  • refractive index difference between the lighting source 12 and the air is about 2.
  • the critical angle for total internal reflection is about 33.9 degree.
  • the lighting source 12 since the lighting source 12 is disposed within the cover 20 , refractive index difference between the lighting source 12 and the UV resin is about 1.5. In this case, the critical angle for total internal reflection is about 52.4 degree, and thus luminance efficiency may be improved.
  • a heat sink for radiating heat of the LED is required.
  • thermal conduction rate of the UV resin is higher than that of the air, a separate heat sink is not required.
  • melting temperature of the UV resin is relative low enough to immerse the lighting source 12 within the UV resin. That is, a general light guide functioning as the cover 20 is made of material injected with relatively high temperature. When the cover 20 is made of the material same as the general light guide and the lighting source 12 is immersed within the cover 20 , then the lighting source 12 may be damaged by the cover 20 with relative high temperature. So, in the exemplary embodiment of the present invention, the cover 20 is made of the UV resin with relatively low melting temperature to immerse the lighting source 12 therewithin.
  • the UV resin may be made of acrylic material with excellent light transmitting characteristic for improving luminance efficiency.
  • the cover 20 is made of acrylic UV resin with composition ratio as (a) Urethane acrylate 20-60 wt %, (b) lobornyl acrylate 20-60 wt %, (c) 2-Hydroxyproyl acrylate 10-40 wt %, (d) 2-Hydroxyethyl methacrylate 9-20 wt %, (e) additive 1-3 wt % per total weight.
  • the printed circuit board 10 and the cover 20 of the lighting apparatus 100 are made of flexible material, so that the lighting apparatus 100 may be bent to match to a rounded surface of a vehicle.
  • the lighting apparatus 100 according to the first exemplary embodiment of the present invention is bent in FIG. 1 .
  • the lighting apparatus 100 may be flat as shown in FIG. 2 then the lighting apparatus 100 may be bent to match with a rounded surface of a vehicle to be mounted thereto.
  • FIG. 2 is a drawing showing a lighting apparatus for a vehicle according to a second exemplary embodiment of the present invention.
  • like reference numerals of the first exemplary embodiment represent the same constituent elements and repeated description will be omitted.
  • the lighting source 12 includes the first lighting source 12 a and the second lighting source 12 b of which each lighting surface 11 faces each other.
  • a lighting source 14 of a lighting apparatus 200 includes a first lighting source 14 a and a second lighting source 14 b which are disposed apart from each other and of which each lighting surface 13 faces the same direction, and a third lighting source 14 c of which a lighting surface faces toward between the first lighting source 14 a and the second lighting source 14 b.
  • each lighting source 14 a , 14 b , and 14 c are disposed alternately, so that reduced numbers of the lighting source 14 may be disposed on the printed circuit board 10 comparing that of the first exemplary embodiment of the present invention.
  • the intensity of radiation reflected by the reflective portion 15 may sufficiently be secured.
  • the lighting surfaces 13 of the lighting sources 14 a , 14 b , and 14 c may be elongated.
  • the lighting apparatus 100 and 200 according to the exemplary embodiments of the present invention is required to reduce total thickness of the apparatus for securing flexibility.
  • manufacturing methods for the lighting apparatus 100 and 200 according to the first and second exemplary embodiment of the present invention will be described. Since the manufacturing methods for the lighting apparatus 100 and 200 according to the first and second exemplary embodiment of the present are the same, so the identical, so the manufacturing method for the lighting apparatus 100 according to the first exemplary embodiment of the present invention will be described as an example.
  • FIG. 3 and FIG. 4 are drawings showing a manufacturing method for a lighting apparatus according to an exemplary embodiment of the present invention
  • FIG. 5 is a flowchart of a manufacturing method for a lighting apparatus according to an exemplary embodiment of the present invention.
  • a suction table 30 is disposed on a manufacturing line for fixing the flexible printed circuit board 10 .
  • the suction table 30 is connected with a vacuum device 60 and negative pressure may be formed within the suction table 30 by the operation of the vacuum device 60 .
  • a plurality of suction hole 35 is formed to the suction table 30 , and the thin and flexible printed circuit board 10 may be fixed to the suction table 30 through the suction hole 35 using the negative pressure formed by the operation of the vacuum device 60 .
  • the lighting source 12 is mounted to the printed circuit board 10 made of flexible material where the reflective portion 15 is adhesive to the upper surface.
  • the printed circuit board 10 may be cut at a predetermined size.
  • the printed circuit board 10 is disposed on the suction table 30 where the suction hole 35 is formed, then the vacuum device 60 is operated to fix the printed circuit board 10 on the suction table 30 through the suction hole 35 at the step S 20 .
  • a boundary frame 40 is held to the suction table 30 for covering circumference of the printed circuit board 10 at the step S 30 .
  • melted resin is supplied within the boundary frame 40 though a resin supplier 50 for the lighting source 12 to be immersed within the resin at the step S 40 .
  • the melted resin is hardened to be the cover 20 , and UV (Ultra Violet) resin may be used.
  • the melted resin requires leveling process for flatting upper surface.
  • the melted resin is viscous, thus leveling with gravity consumes lots of time.
  • a vibrator 70 may be equipped for vibrating the suction table 30 to level the resin at the step S 50 so that leveling process time may be reduced.
  • the resin is hardened at the step S 60 .
  • the suction table 30 may be hardened passing through a hardening device.
  • the hardening device may be a UV hardening device.
  • the boundary frame 40 is removed from the suction table 30 and then manufacturing of the lighting apparatus 100 according to the first exemplary embodiment of the present invention is completed.
  • the lighting apparatus 100 and 200 is flexible, and is easily mounted to a vehicle without regard to shape of a mounting portion to match the design of a vehicle with flexibility.
  • weight of a vehicle may also be reduced.
  • the lighting source is disposed within the cover, thus luminance efficiency may be enhanced comparing a general lighting apparatus which is disposed outside of a cover.
  • the lighting apparatus according to the exemplary embodiments of the present invention may be widely used as various lighting apparatus as a stop lamp, a turn signal lamp and so on.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)
  • Arrangements Of Lighting Devices For Vehicle Interiors, Mounting And Supporting Thereof, Circuits Therefore (AREA)
  • Fastening Of Light Sources Or Lamp Holders (AREA)
US14/015,590 2012-08-30 2013-08-30 Lighting apparatus for vehicle and manufacturing method for the same Abandoned US20140063830A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US14/923,143 US9992877B2 (en) 2012-08-30 2015-10-26 Manufacturing method for a lighting apparatus for a vehicle

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
KR10-2012-0095826 2012-08-30
KR1020120095826A KR20140028768A (ko) 2012-08-30 2012-08-30 자동차의 조명장치 및 그것의 제조방법

Related Child Applications (1)

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US14/923,143 Division US9992877B2 (en) 2012-08-30 2015-10-26 Manufacturing method for a lighting apparatus for a vehicle

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US20140063830A1 true US20140063830A1 (en) 2014-03-06

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US14/923,143 Active 2034-05-05 US9992877B2 (en) 2012-08-30 2015-10-26 Manufacturing method for a lighting apparatus for a vehicle

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US (2) US20140063830A1 (zh)
KR (1) KR20140028768A (zh)
CN (1) CN103672653B (zh)
DE (1) DE102013109436A1 (zh)

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US20170284623A1 (en) * 2016-03-31 2017-10-05 GM Global Technology Operations LLC Methods and apparatus for free-form illumination assemblies
EP3388732A1 (en) * 2017-04-14 2018-10-17 Valeo Iluminacion Lighting device and manufacturing method
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US9992877B2 (en) 2018-06-05
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CN103672653B (zh) 2016-06-08
CN103672653A (zh) 2014-03-26
DE102013109436A1 (de) 2014-03-06

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