WO2011116635A1 - 一种led灯发光单元及所形成的汽车、摩托车led前照灯 - Google Patents

一种led灯发光单元及所形成的汽车、摩托车led前照灯 Download PDF

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Publication number
WO2011116635A1
WO2011116635A1 PCT/CN2011/000494 CN2011000494W WO2011116635A1 WO 2011116635 A1 WO2011116635 A1 WO 2011116635A1 CN 2011000494 W CN2011000494 W CN 2011000494W WO 2011116635 A1 WO2011116635 A1 WO 2011116635A1
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WO
WIPO (PCT)
Prior art keywords
light
cup
led
lamp
panel
Prior art date
Application number
PCT/CN2011/000494
Other languages
English (en)
French (fr)
Inventor
代天荣
李易
Original Assignee
重庆科鹰电气有限公司
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
Priority claimed from CN2010201383840U external-priority patent/CN201680258U/zh
Priority claimed from CN2010201644253U external-priority patent/CN201680264U/zh
Priority claimed from CN2010205633597U external-priority patent/CN201866671U/zh
Application filed by 重庆科鹰电气有限公司 filed Critical 重庆科鹰电气有限公司
Publication of WO2011116635A1 publication Critical patent/WO2011116635A1/zh

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/60Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by a variable light distribution
    • F21S41/65Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by a variable light distribution by acting on light sources
    • F21S41/663Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by a variable light distribution by acting on light sources by switching light sources
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141Light emitting diodes [LED]
    • F21S41/143Light emitting diodes [LED] the main emission direction of the LED being parallel to the optical axis of the illuminating device
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141Light emitting diodes [LED]
    • F21S41/151Light emitting diodes [LED] arranged in one or more lines
    • F21S41/153Light emitting diodes [LED] arranged in one or more lines arranged in a matrix
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/24Light guides
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21SNON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/25Projection lenses
    • F21S41/27Thick lenses

Definitions

  • the invention belongs to the LED light source technology, and particularly relates to an LED light emitting unit and a light source having a high beam or low beam effect.
  • LED Light Emitting Diode
  • LED Light Emitting Diode
  • the theoretical life of LEDs exceeds 100,000 hours, and the luminous efficiency is as high as 90%.
  • the same luminous flux consumes only 8% of incandescent lamps, and has the advantages of significant green and low carbon. LEDs have been widely used in the field of lighting worldwide.
  • automobile and motorcycle headlights front combination lamps
  • halogen lamps as light sources, and reflect light in front of the vehicle through reflection in reflective bowls. Since the light effect of the halogen light source is lower than that of the LED, the heat generation is large, the life is short, and the utilization of the light reflected by the reflective bowl is low, the existing automobile headlights generally have high energy consumption, weak illumination, and heat generation. Large, short life (such as the filament is easy to burn, easy to break), there are certain security risks.
  • LEDs Due to the wide application of LEDs and their significant advantages, many people have tried to use LEDs as headlights for automobiles and motorcycles. However, due to the unreasonable design of the LED lamp lighting unit, there is no light utilization factor of the lighting unit. High, poor heat dissipation, severe light fading, unable to form ideal high beam spots and near-light spots, and can not meet the requirements of relevant national standards. Not widely used.
  • the object of the present invention is to provide a new LED light emitting unit and the formed automobile and motorcycle LED headlights in order to improve the brightness of the light emitted by the light source and to achieve the forming spot.
  • the ideal requirements, in line with the relevant national standards, are a good solution to the problems of the original motorcycles and car headlights.
  • the present invention firstly designs a special structure of the light-emitting unit - confirmation
  • the light unit is composed of a lens type lamp cup, an LED lamp bead and a circuit board.
  • the lamp cup is preferably injection molded using a PMMA optical material having a light transmittance of 92.8% or more. Since the refractive index of the PMMA is greater than the refractive index in the air, total reflection of the incident light satisfying the critical angle of total reflection can be achieved.
  • the lens type lamp cup is a solid body, and the side surface of the lamp cup is a parabolic reflection surface formed by a parabola rotating along the axial direction of the lamp cup; or a spherical reflection surface formed by a circular arc line rotating along the axial direction of the lamp cup. , or a freeform surface.
  • the LED lamp bead mounting hole is left in the center of the cup holder of the lamp cup, and the hole top of the LED lamp bead mounting hole is a lenticular lens (composed of R1 and R2 in the drawing) or a single-sided convex lens structure (such as R1 in the drawing) Or R2), or a concave lens.
  • the key to the design of the lamp cup is to ensure that the parabolic or surface of the spherical reflector or the free-form surface coincides with the focus of the lenticular or single-sided convex or concave mirror.
  • the LED lamp bead is formed by a light-sealed lamp bead.
  • the LED lamp bead is mounted on the circuit board, inserted into the LED lamp bead mounting hole of the cup holder of the lens type lamp cup, and the parabolic reflecting surface or the spherical reflecting surface of the lamp cup is arranged. Or the coincident focus of the free-form surface and the lenticular lens or the single-sided convex lens or the concave lens falls between the center of the LED lamp bead, that is, between the real focus and the virtual focus, or falls on the solid focus, or falls on the virtual focus.
  • the real focus of the LED lamp bead is the LED chip position or the LED lamp bead phosphor layer.
  • the lens cup is secured to the circuit board by a cup holder.
  • the cup top structure of the lamp cup is also critical, the cup top of the lamp cup may be a full plane or a concave surface, or the top surface of the cup may be distributed with at least one vertically arranged cylinder surface; or the center of the cup top may be concave to form a lenticular lens. Face or plane, the rest of the top of the cup is flat or distributed at least one vertically arranged cylinder; or in order to reduce the weight, the top of the cup is a step which is gradually lowered toward the center of the cup, and the step surface is flat or distributed with a cylinder This can also achieve the same effect as the previous structure.
  • a cup with a cup top as a flat or concave surface without a cylindrical mirror called an A-type lamp cup
  • a cup-shaped mirror with a cylindrical mirror called a B-type lamp cup
  • the light from the lamp bead passes through the A-type lamp cup.
  • the reflection and transmission will form a circular spot
  • the reflection and transmission of the light emitted by the lamp bead through the B-type lamp cup will form a rectangular spot or an elliptical spot, thereby obtaining a low beam or high beam effect.
  • the shape of the cup top of the lamp cup is different.
  • the top of the cup of the lamp cup is distributed with at least one vertically arranged cylinder surface, or the side or plane of the cup top is concavely formed to form a lenticular lens, and the rest of the cup top is at least one vertically arranged.
  • Cylindrical surface including the case where the cylindrical surface is distributed on the step surface).
  • the cup top of the lamp cup is a full plane or a concave surface, or a side or plane of the cup top center concavely forming a lenticular lens, and the rest of the cup top is a plane (including the step surface is a plane)
  • the top of the cup cup is not distributed with a cylinder.
  • the LED lamp illumination unit When the structure of the LED lamp illumination unit satisfies the above conditions, it can ensure that the light emitted by the light-emitting chip of the lamp bead is reflected and totally reflected by the parabolic reflection surface or the spherical reflection surface or the free-form surface of the lamp cup and transmitted by the convex lens of the lamp cup. It can be "substantially" emitted in parallel along the optical axis, thereby significantly improving the utilization of light, and the utilization of light can reach 95%.
  • the above-mentioned “basic” is because the surface area of the LED chip of the LED lamp bead is usually small.
  • the light output angle is less than 10 degrees, so that the light emitted through the lamp cup can be regarded as substantially effective light.
  • the light emitted by the lamp bead forms a circular spot through the reflection and transmission of the A-type lamp cup (or high-beam illumination unit), and forms a rectangular spot or an elliptical spot by reflection and transmission of the B-type lamp cup (or low-beam light-emitting unit).
  • the low beam spot is formed with a dark cut-off line, and the two lamp cups A and B can be organically combined to obtain an ideal spot.
  • the present invention further designs a motorcycle LED headlamp light source formed using the above-described lighting unit, which includes a low beam panel and a high beam panel.
  • the low beam panel is composed of at least two of the lighting units mounted on a lamp holder, wherein at least one of the lighting units is a lighting unit of a B-type lamp cup structure, and the B-type lamp cup structure is adjusted according to specific requirements. The proportion of the unit.
  • the high beam panel is also constructed by mounting at least two of the lighting units on a light fixture, PT/CN2011/000494
  • At least one of the middle light-emitting units is a light-emitting unit of the ⁇ -type lamp cup structure, and the ratio of use between the light-emitting unit and the other light-emitting units is determined according to specific requirements.
  • the two light panels are arranged in a close-up or left-right manner in the lamp housing; and when the low-beam panel is under the high beam panel, the angle between the light-emitting surfaces of the two panels is maintained at 16 1 ° to 180 ° When the high beam panel is on and the low beam panel is below, the angle between the exit surfaces of the two panels is maintained at 18 1 ° ⁇ 200 °; when the two panels are arranged one left and one right, the low beam
  • the light-emitting surface of the plate is inclined by 1 ° ⁇ 20 ° from the light-emitting surface of the far-light plate.
  • the high beam does not illuminate.
  • the low beam is tilted to the ground at a certain angle, and the working illumination range can be extended from the front wheel of the motorcycle to 25m, forming a rectangular main spot with a height of 0.5m, a width of 8m, plus scattered light on both sides, which can not directly touch each other. Under the premise of the driver of the car, the road and both sides are illuminated.
  • the high beam When the high beam is activated, it can focus on horizontally emitting light, illuminating distant pedestrians, vehicles, road signs, and the like.
  • the headlight front combination lamp
  • the low beam lamp can also work simultaneously when the high beam lamp is operated, thereby being able to move from the front wheel of the motorcycle to the far side.
  • the position is illuminated, ensuring no black spots within 25 meters in front of the motorcycle, and the illumination range is wide, which is more convenient for safe driving.
  • the light-emitting unit designed by the invention can be equipped with various shapes of the light piece, the rear shell and the power source to form various types of motorcycle headlight assembly, which is suitable for various types of motorcycle headlights.
  • an automotive LED headlamp can be formed by using the above-described LED lamp lighting unit, which includes a low beam panel, a high beam panel, a rear panel, and a light sheet.
  • the low beam panel and the high beam panel are mounted in the rear case, and the lamp cover is placed in front of the light exit surface of the low beam panel and the high beam panel.
  • the low beam panel is constructed by mounting at least two of the light emitting units on a light fixture, wherein at least two of the light emitting units are low beam light emitting units, and the proportion of the low beam light emitting units is adjusted according to specific requirements.
  • the cup top cylinders of the plurality of low-beam light-emitting units in the low-beam light panel may all be vertically arranged, or may be partially arranged vertically, and the other part is rotated clockwise by 1 ° to 22° in the vertical direction. Column.
  • the high-beam panel is also constructed by mounting at least two of the light-emitting units on a light fixture, wherein at least one of the light-emitting units is a high-beam light-emitting unit, and the proportion of use of the light-emitting unit is determined according to specific requirements.
  • the two light panels are arranged in a one-up or left-right manner in the lamp housing, and the two are divided into two separate portions arranged next to each other or connected to each other, or may be formed as a whole.
  • the angle between the two panels is maintained at 16 1 ° ⁇ 180 °; when the high beam panel is above and the low beam panel is below, the two panels are illuminated.
  • the angle of the face is maintained at 18 1 ° ⁇ 200 °; when the two light plates are arranged one left and one right, the light exit surface of the low beam light plate is inclined by 1 ° ⁇ 20 ° from the light exit surface of the far light light plate.
  • the headlight includes an LED light emitting unit, a light board, a lamp holder, a light piece and a rear case, and The transparent cover; the light board and the LED light emitting unit are installed in the lamp holder, and the light piece is mounted on the lamp holder or the light board, and is located in front of the light emitting surface of the LED light emitting unit.
  • the lamp holder is a heat sink base made of aluminum alloy or aluminum.
  • the angle between the light emitted from the light emitting unit of the LED light and the vertical line of the plane of the light plate is between 0.5 and 22 degrees.
  • at least one of the LED light-emitting units has a vertically arranged cylinder surface (including a cylindrical surface on the step surface), Forming a low beam portion of the headlight;
  • the top surface of the remaining LED light emitting unit of the lamp holder is a plane (including a plane with a step surface) or a concave surface, and at the same time, at least one LED light emitting unit emits light It coincides with the vertical line of the plane of the light board, that is, the light emitting surface of the LED light emitting unit coincides with the plane of the light board to form a high beam part of the headlight.
  • the high beam portion when the low beam portion is separately activated, the high beam portion is not lit.
  • the low-light part is inclined to a certain angle to the ground, and the working illumination range can be extended from the front wheel to 25m, forming a height of 0.5m (the right end of the cut-off line is rotated upward from the center point by 0.1° to 22°), and the width is 8m.
  • the main square of the rectangle, plus the scattered light on both sides, can be used without the direct contact of the other party. Illuminate the road ahead and the pedestrians on the right.
  • the high beam portion When the high beam portion is activated, it can concentrate on horizontally emitting light to illuminate distant pedestrians, vehicles, road signs, and the like.
  • the headlights use LED light sources, the required power is not large, and the low beam lights can work simultaneously when the high beam lights work, thereby taking photos from the front wheels of the car and the motorcycle to the far side. Bright, to ensure that there are no black spots within 25 meters in front of cars and motorcycles, and the illumination range is wide, which is more conducive to safe driving.
  • the present invention has the following significant advantages - by properly designing the secondary optical system, that is, the structure of the lamp cup (lens), and the mounting position of the lamp bead in the lamp cup, the light-emitting brightness of the light-emitting unit is made. And the molding spot can achieve the desired requirements.
  • the use of such a light-emitting unit as a light source for LED cars and motorcycle headlights is compared with conventional headlamps: power is reduced by 75%; illumination is doubled or multiplied; no heat is generated, and LED lamp beads are not afraid of water, Not afraid of falling rings, life can be extended several times; can achieve the goal of low beam at the same time when driving the high beam, eliminating the safety hazard.
  • FIG. 1 is a schematic view showing the structure of a light-emitting unit of a B-type lamp cup (a lenticular lens).
  • FIG. 1A is an optical path diagram of a light-emitting unit of a B-type lamp cup.
  • Figure 1AA is an optical path diagram of the partial cylindrical surface of the cup top of Figure 1A.
  • Figure 1B is a plan view of the light-emitting unit of the B-type lamp cup
  • FIG. 2 is a schematic view showing the structure of a light-emitting unit of a B-type lamp cup (single-convex lens).
  • FIG. 2A is an optical path diagram of a light-emitting unit of a B-type lamp cup.
  • FIG. 2B is a schematic structural view of a light-emitting unit of another type B lamp cup (concave lens, step surface).
  • FIG. 2C is a schematic structural view of a light-emitting unit of another type B lamp cup (concave lens, step surface).
  • FIG. 3A is an optical path diagram of the light-emitting unit of the A-type lamp cup
  • FIG. 4 Schematic diagram of the light-emitting unit of another type A lamp cup (faceted convex lens)
  • Fig. 4A is an optical path diagram of the light-emitting unit of the type A lamp cup
  • FIG. 4B is a schematic structural view of a light-emitting unit of another type A lamp cup (concave lens, step surface).
  • FIG. 4C is a schematic structural view of a light-emitting unit of another type A lamp cup (concave lens, step surface)
  • Figure 5 is a light path diagram of a lamp bead (virtual focus and real focus coincide)
  • Figure 6 is a light path diagram of another lamp bead ((virtual focus and real focus do not coincide)
  • Figure 7 is a schematic view showing the structure of a motorcycle LED headlamp light source
  • Figure 7A is a side view of Figure 7;
  • Figure 8 is an outline view of a form of automotive LED headlamp
  • Figure 8A is a cross-sectional view taken along line A-A of Figure 7;
  • Figure 9 is a layout view of four forms of low beam and high beam panels in a headlight;
  • Figure 9A is a first form;
  • Figure 9B is a side view of Figure 7A;
  • Figure 9C is a second form
  • Figure 9D is a third form
  • Figure 9E is the fourth form.
  • Figure 10 is an outline view of a form of motorcycle LED headlamp
  • Figure 10A is a cross-sectional view taken along line A-A of Figure 7;
  • Figure 11 is a plan layout view of a second form of headlamp
  • Figure 12 is a plan view of a headlamp of a third form.
  • the light-emitting unit is a B-type lamp cup, which is composed of a lens type lamp cup 15, an LED lamp bead 12 and a circuit board 11 (a plurality of lens type lamp cups and LED lamps can be mounted on one circuit board) Beads, forming a plurality of light-emitting units).
  • the lamp cup is injection molded by a PMMA optical material having a light transmittance of 92.8% or more, and is a solid body lens.
  • the side surface 14 of the lamp cup is a parabolic reflecting surface formed by a parabola rotating along the axial direction of the lamp cup (of course, it may be a spherical reflecting surface formed by a circular arc line rotating along the axial direction of the lamp cup, or a free curved surface. ).
  • the LED bead mounting hole is left in the center of the cup holder of the lamp cup, and the top of the hole of the LED lamp bead mounting hole is a lenticular lens 16 (composed of R1 and R2) Structure.
  • the lenticular lamp cup is fixed to the circuit board 11 by a cup holder.
  • the focus of the parabolic reflecting surface of the lamp cup coincides with the focus of the lenticular lens, and the coincidence point is point A.
  • LED lamp bead 12 uses a light-sealed lamp bead, see Figure 5, which is a single-chip lamp bead.
  • the size of the light-emitting chip is 1 mm X 1 mm.
  • the LED lamp bead 12 is mounted on the circuit board 11 and inserted into the LED lamp bead mounting hole of the cup holder of the lens type lamp cup.
  • the coincidence focus of the parabolic reflecting surface of the lamp cup and the lenticular lens falls on the LED lamp bead light.
  • the real focus (the real focus and the virtual focus of the bead are coincident), that is, the position of the LED chip 13 of the LED bead coincides with the parabolic reflection surface of the lamp cup and the focus of the lenticular lens. Referring to FIG.
  • the light emitted by the light-emitting chip 13 of the lamp bead is reflected and totally reflected by the parabolic reflecting surface of the lamp cup, and the light transmitted through the convex lens of the lamp cup can be "substantially" emitted parallel along the optical axis, thereby significantly increasing the light. Utilization rate.
  • the top of the cup of the lamp cup is distributed with a plurality of vertically arranged cylindrical faces 17 respectively.
  • the light emitted from the lens at the top of the lamp cup through a plurality of cylinders 17 is as shown in FIG. 1AA, and the cylindrical lenses will emit light levels. Stretching into a rectangular spot or a rectangular (such as an elliptical) spot, thereby achieving the low beam effect required for motorcycle headlamps.
  • FIG. 2 and FIG. 2A show another structure of a light-emitting unit using a B-type lamp cup, which is different from the structure of FIG. 1 in that the top of the hole of the LED lamp bead mounting hole is a single-sided convex lens 18, and the like.
  • the structure is the same, and the illuminating effect of the former illuminating unit can also be achieved.
  • FIG. 2B and 2C show another structure of a light-emitting unit using a B-type lamp cup, which is different from the structure of FIG. 1 in that the top of the hole of the LED lamp bead mounting hole is a concave lens 18', the top of the cup
  • the step surface is distributed with a cylindrical surface, and other structures are the same, and the luminous effect of the former light-emitting unit can also be achieved.
  • 3 and 3A, 4, 4A, 4B and 4C show the structure of the light-emitting unit using the A-type cup cup, which is basically the same as the structure of the light-emitting unit of Figs. 1 and 2, except that The top of the cup adopts a plane or a step plane, thereby producing a different light-emitting effect, and the light emitted by the lamp bead is formed into a circular spot by reflection and transmission of the A-type lamp cup. This achieves the high beam effect required for motorcycle headlamps.
  • the first few structures use a lamp with a special structure, that is, the lamp bead.
  • the real and virtual focus of the outgoing light are coincident.
  • the present illumination unit can adopt any other form of lamp bead.
  • the real focus A ie, the position of the light-emitting chip
  • the light-emitting unit formed by the lamp bead is as shown in FIG. 4 and FIG. 4A.
  • the position of the LED lamp bead 12 is such that the coincidence focus of the parabolic reflecting surface of the lamp cup and the lenticular lens falls on the LED lamp bead 12 to emit light.
  • the coincidence focus can also be placed on the illuminating center, that is, the real focus, or at any position between the virtual focus and the real focus, which can make the illuminating unit obtain the desired illuminating effect.
  • a motorcycle LED headlamp light source formed by using the above-described light emitting unit is shown in Figs. 7 and 7A, and the light source includes a low beam panel 3 and a high beam panel 2.
  • the low beam panel 3 is constructed by arranging three light-emitting units 1B with a plurality of cylinders on top of each other on the lamp holder.
  • the high beam panel 2 is provided with eight cup-shaped light-emitting units 1A arranged side by side on the lamp holder.
  • a certain proportion of the light-emitting units 1B can be installed on the low-beam panel 3 as needed, and a certain proportion of the light-emitting units 1A are mounted on the high-beam panel 2.
  • the two light panels are arranged next to each other in the lamp housing, and the angle between the low beam panel 3 and the light exit surface of the high beam panel 2 is maintained at 187°.
  • the specific installation of the headlights is to mount the circuit board with the LED lamp bead corresponding to the cup bottom mounting hole of each lamp cup (lens) of the headlight, and then integrate with the lamp piece and the rear case to form a headlight total. to make.
  • FIGS. 8 and 8A An automotive LED headlamp formed using the above-described lighting unit is shown in FIGS. 8 and 8A, and the light source includes a low beam panel 2, a high beam panel 3, a rear casing 6, and a bulb 4.
  • the low beam panel 3 and the high beam panel 2 are mounted in the rear casing 6, and the lamp panel 4 is placed in front of the light exit surface of the low beam panel and the high beam panel.
  • the high beam panel 2 and the low beam panel 3 are arranged next to each other in the rear housing 6, and the angle between the exit surfaces of the two panels is maintained at 187°.
  • the specific installation of the headlights is to mount the circuit board 8 with the LED lamp beads soldered to the bottom mounting holes of the lamp cups of the headlights to form the light-emitting units 1, and the light-emitting unit 1 is fixed on the support frame 7 and the support plate. 5, forming a low beam panel 2 and a high beam panel 3, and then The lamp piece 4 and the rear case 6 are assembled into one body, that is, constitute a car headlight.
  • the arrangement of the light-emitting units on the high-beam panel 2 and the low-beam panel 3 can be variously combined, as shown in Fig. 9, as follows:
  • the low beam panel 3 is composed of seven low-beam illumination units 1B mounted side by side on a lamp holder, wherein the cup top cylinders of the first, third, fifth and seventh low-beam illumination units in the illumination unit are arranged. It is vertically arranged, and the cylinder faces of the cup tops of the 2nd, 4th, and 6th low-beam light-emitting units are arranged in a clockwise direction by about 15° in the vertical direction.
  • the high beam panel 2 is composed of 14 high beam illumination units 1A mounted in two rows on a light fixture.
  • the low beam panel 3 is composed of five low beam illumination units 1B and two high beam illumination units 1A mounted side by side on a light fixture, wherein the low beam illumination unit 1B is set at the first.
  • the cup top cylinders of the low-beam light-emitting units at the first and seventh positions are vertically arranged, and the cylinder tops of the second-, fourth-, and sixth-position low-beam light-emitting units are The vertical direction is rotated by about 15° in the clockwise direction, and the high-beam illumination unit 1A is placed at the 3rd and 5th positions.
  • the high beam panel 2 is composed of 14 illumination units installed in two rows on one lamp holder, wherein the first row 7 is all the high beam illumination unit 1A, and the 3rd and 5th positions of the second row are the low beam illumination unit. 1B, the rest are high beam illumination units.
  • the low beam panel 3 is composed of seven low-beam illumination units 1B mounted side by side on a lamp holder, wherein the cup top cylinders of the first, third, fifth and seventh low-beam illumination units in the illumination unit are arranged. It is vertically arranged, and the cylinder faces of the cup tops of the 2nd, 4th, and 6th low-beam light-emitting units are arranged in a clockwise direction by about 15° in the vertical direction.
  • the high beam panel 2 is composed of 14 illumination units installed in two rows on a lamp holder, wherein the first row of 7 is all the high beam illumination unit 1A, and the third row of the 3rd and 5th positions is the low beam illumination unit. 1B, the rest are high beam illumination units.
  • the low beam panel 3 is composed of five low-beam illumination units 1B and two high-beam illumination units 1A mounted side by side on a light fixture, wherein the low-beam illumination unit 1B is disposed at the first and second ends.
  • the cup top cylinders of the low beam illumination units at the 1st and 7th positions are vertically arranged, and the cylinder tops of the 2, 4, and 6 position low beam illumination units are vertically
  • the direction is rotated clockwise by about 15 °, and the high beam illumination unit 1A is placed at the 3rd and 5th positions.
  • High beam The board 2 is composed of 14 high-beam light-emitting units 1A installed in two rows on one lamp holder.
  • the above embodiments are all shown in the manner of placing the low beam and the high beam on the upper and lower sides, and the arrangement of the two lamps on the left and right is also a common way.
  • the arrangement needs to pay attention to setting the light exit surface of the low beam to be compared.
  • the light beam of the high beam is inclined downward by 1 ° ⁇ 20 °.
  • the headlamp includes an LED lamp lighting unit 1, a light board 9, a lamp holder 10, a lamp piece 4 and a rear case 6 and The transparent cover 11, the light board 9 is installed in the socket 10, and the LED light emitting unit 1 is mounted on the light board 9.
  • the light board 9 is provided with a hole corresponding to the size of the LED light emitting unit, and the LED light emitting unit is installed in the hole.
  • the lamp piece 4 is mounted on the lamp holder 10 and located in front of the light-emitting surface of the LED lamp light-emitting unit.
  • the lamp holder 10 is fitted in the rear case 6 and the front side is covered by the transparent cover 11.
  • the lamp holder 10 is preferably an aluminum alloy heat sink.
  • five LED lamp illumination units are arranged side by side on the lamp board 7, wherein two LED lamp illumination units form a low beam portion 12, and their outgoing rays are perpendicular to the plane of the lamp panel 9 of the lamp panel 9. ° Angle, and the top surface of the two LED light-emitting units is in the form of vertical cylinders.
  • the remaining three LED light-emitting units on the lamp panel form the high beam portion 13 of the headlights, and their cup top surfaces are flat, and the light emitted from the LED light-emitting units coincides with the vertical line of the plane of the light board, that is, the top of the cup
  • the illuminating surface is consistent with the plane of the light panel and has no angle.
  • LED light-emitting units are arranged in many forms, and the following are exemplified, but are not limited to the following forms:
  • the light-emitting unit of the light-emitting unit of the light-emitting panel 9 is 0. 5°. ⁇ 22° angle, but of the two LED light-emitting units, only one of the top surfaces of the cups is in the form of vertical cylinders and the other is flat.
  • the remaining three LED light-emitting units on the lamp board form the high beam portion 13 of the headlights, and the top surfaces of the cups are all flat, and the light-emitting surfaces of the cup tops of the LED light-emitting units are consistent with the plane of the light board, and have no angle. .
  • the figure also uses five LED light-emitting units, two of which have LEDs.
  • the light-emitting unit forms a low-beam portion 12, and the vertical line of the light emitted from the light-emitting panel of the light board 9 is at an angle of 0.5° to 22°, and the top surface of the two LED light-emitting units is vertically arranged.
  • the cylindrical form, the cylinder is dense.
  • the remaining three LED light-emitting units on the lamp panel form the high beam portion 13 of the headlights, and the light-emitting surfaces of the cup tops of the LED light-emitting units are identical to the plane of the light panel, and have no angle.
  • the top surface of their cups is also in the form of cylinders arranged vertically, but the cylinders are sparse, that is, the spacing is relatively wide, and this form can also achieve the high beam effect.
  • the number of LED light emitting units can also be increased as needed, and the positions of the low beam portion and the high beam portion can be varied.
  • the low beam portion forms the angle so that the tilting direction of the top surface of the LED lamp unit is inclined downward with respect to the top surface of the cup portion of the high beam portion.
  • the cup top of the LED lamp lighting unit preferably adopts the step form of Fig. 2B, Fig. 2C or Fig. 4B, Fig. 4C, which can reduce the weight and save materials.

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Description

2011/000494 说 明 书
一种 LED灯发光单元及所形成的汽车、 摩托车 LED前照灯 技术领域
本发明属于 LED 光源技术, 具体涉及一种具有远光或近光效果的 LED灯发光单元及光源。
背景技术
LED (发光二极管)被誉为第四代光源, 其具有寿命长、光效高、无 辐射的优点。 LED的理论寿命超过 10万个小时, 发光效率高达 90%, 而 相同光通量的能耗仅为白炽灯的 8%, 具有显著的绿色、 低碳之优点。 在 世界范围内 LED在照明领域内己得到广泛应用。
目前汽车、 摩托车前照灯 (前组合灯) 主要采用卤素灯为光源, 通 过反光碗反射的方式将光反射于车前方。 由于卤素灯光源的光效较 LED 低、发热量大、 寿命短, 以及采用反光碗反射的方式光的利用率低, 故现 有的汽车前照灯普遍存在能耗高、 照明弱、 发热量大、 寿命短 (如灯丝易 烧断、 易破碎)的问题, 存在一定的安全隐患。
由于 LED的广泛应用及其所具有的显著优点,许多人都试图采用 LED 作为汽车、摩托车的前照灯光源,但是由于对 LED灯发光单元的结构设计 不合理, 存在发光单元光利用率不高、 散热不好、 光衰严重, 无法形成理 想的远光光斑和近光斑等问题,达不到国家有关标准的要求。未能广泛使 用。
发明内容
本发明技术的目的在于针对现有技术存在的上述不足, 提出一种新 的 LED灯发光单元及所形成的汽车、 摩托车 LED前照灯, 以提高光 源的出射光亮度, 并使成型光斑达到理想的要求, 符合国家有关标准, 很 好地解决原摩托车、 汽车前照灯存在的问题。
本发明的技术方案如下:
为了达到上述目的, 本发明首先对发光单元的结构进行了特殊设计- 确认本 发光单元是由透镜式灯杯、 LED灯珠和电路板组成。 灯杯最好采用 透光率 92.8%以上的 PMMA光学材料注塑成型, 由于 PMMA的折射率 大于空气中的折射率, 可使满足全反射临界角的入射光实现全反射。
透镜式灯杯是一实心体,灯杯的侧表面是由抛物线沿灯杯轴向回转而 形成的抛物反射面;或是由一段圆弧线沿灯杯轴向回转而形成的球型反射 面, 或为自由曲面。
在灯杯的杯座中心留有 LED灯珠安装孔, LED灯珠安装孔的孔顶为 双面凸透镜 (如附图中的 R1和 R2组成) 或单面凸透镜结构 (如附图中 的 R1或 R2), 或凹透镜。
该灯杯设计的关键是要保证灯杯的抛物反射面或球型反射面或自由 曲面的焦点与双面凸透镜或单面凸透镜或凹面镜的焦点重合。
LED灯珠采用一次光封成型的灯珠, LED灯珠安装在电路板上, 插 入透镜式灯杯的杯座的 LED灯珠安装孔中, 并使灯杯的抛物反射面或球 型反射面或自由曲面与双面凸透镜或单面凸透镜或凹透镜的重合焦点落 于 LED灯珠发光中心即实焦点与虚焦点之间, 或者落于所述实焦点上, 或者落于所述虚焦点上。 我们知道, LED灯珠出射光的实焦点即为 LED 灯珠的发光芯片位置或 LED灯珠荧光粉层。 所述透镜式灯杯通过杯座固 定在电路板上。
该灯杯的杯顶结构也比较关键, 灯杯的杯顶可以为一整平面或凹面, 或者杯顶面分布至少一条竖直排列的柱面;或者杯顶中心下凹形成双面凸 透镜的一个面或平面,杯顶的其余部分为平面或分布至少一条竖直排列的 柱面; 或者为了减轻重量,杯顶为多圈向杯中心逐级降低的台阶, 台阶面 为平面或分布有柱面, 这样也可以达到与前面的结构一样的效果。
为了便于区分,我们将杯顶为平面或凹面没有分布柱面镜的灯杯叫做 A型灯杯, 杯顶分布有柱面镜的叫做 B型灯杯, 灯珠发出的光通过 A型 灯杯的反射和透射会形成圆形光斑, 灯珠发出的光通过 B型灯杯的反射 和透射会形成矩形光斑或椭圆形光斑, 由此可获得近光或者远光效果。 对于近光发光单元和远光发光单元,其灯杯的杯顶形状有所区别。对 于近光发光单元,其灯杯的杯顶分布至少一条竖直排列的柱面,或者杯顶 中心下凹致形成双面凸透镜的一面或平面,杯顶的其余部分为至少一条竖 直排列的柱面 (包含阶梯面上分布柱面的情况)。 而对于远光发光单元, 其灯杯的杯顶为一整平面或凹面,或者其杯顶中心下凹致形成双面凸透镜 的一面或平面, 杯顶的其余部分为平面 (包含阶梯面是平面的情况), 远 光发光单元的灯杯杯顶没有分布有柱面。
LED灯发光单元在结构满足上述条件的情况下, 就可以保证灯珠的 发光芯片发出的光经灯杯的抛物反射面或球面反射面或自由曲面反射和 全反射和经灯杯凸透镜透射的光可 "基本"沿光轴平行出射, 由此显著提 高光的利用率, 光的利用可达 95%。
上述所说"基本", 是因为 LED灯珠的发光芯片表面积通常很小, 对 于本发光单元,最好选择单颗芯片的灯珠,且芯片的发光面积在 9平方毫 米内为佳,这样芯片中心与边缘的发出光经灯杯的反射面反射和经凸透镜 透射形成的散射角 Θ1=Θ2 (如图 1Α、 图 2Α、 图 3Α所示), 且小于 ± 10 ° ,从而可以保证 LED芯片发出光经过本灯杯透射后出光角度小于 10度, 因此可视为通过灯杯的出射光基本为有效光。
灯珠发出的光通过 A型灯杯 (或远光发光单元) 的反射和透射形成 圆形光斑, 通过 B型灯杯 (或近光发光单元) 的反射和透射形成矩形光 斑或椭圆形光斑。为了获得近光或远光两种不同的发光效果,使近光光斑 形成上暗下明的截止线, A、 B两种灯杯可有机组合而得到理想的光斑。
基于以上发光单元,, 本发明进一步设计了利用上述发光单元形成的 摩托车 LED前照灯光源, 其包括近光灯板和远光灯板。
所述近光灯板由至少两个所述发光单元安装在一个灯架上构成,其中 发光单元中至少有一个是 B型灯杯结构的发光单元, 并根据具体要求调 节 B型灯杯结构发光单元的比例。
所述远光灯板也由至少两个所述发光单元安装在一个灯架上构成,其 P T/CN2011/000494
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中发光单元中至少有一个是 Α型灯杯结构发光单元, 根据具体要求确定 这种发光单元与其它发光单元之间的使用比例。
所述两灯板在灯壳中一上一下或左右方式紧邻布置安装;且当近光灯 板在上远光灯板在下时,两灯板出光面的夹角保持在 16 1 ° 〜180° ; 当 远光灯板在上而近光灯板在下时, 两灯板出光面的夹角保持在 18 1 ° 〜 200° ; 当两灯板为一左一右布置时, 所述近光灯板的出光面较远光灯板 的出光面向下倾斜 1 ° 〜20° 。
摩托车前照灯工作方式及光照效果如下:
当单独启动近光灯时,远光灯不亮。近光灯由于向地面倾斜一定角度, 工作光照范围可以从摩托车前轮延伸至 25m远, 形成高不过 0. 5m, 宽 8m 的矩形主光斑, 加两侧散射光, 可在不直射对方来车驾驶员的前提下, 照 亮前进路面及两侧。
当启动远光灯时, 其能集中形成水平出射光, 照亮远方行人、 车辆、 道路牌等。
而且,本前照灯(前组合灯)由于采用的是 LED光源,所需功率不大, 在远光灯工作时近光灯也可以同时工作,由此可将从摩托车前轮至远方的 位置都照亮, 保证摩托车前方 25米内无黑斑, 照亮范围宽广, 更有利安 全行驶。
本发明设计的发光单元可以配以各种不同造型的灯片、后壳、电源形 成各种造型摩托车前照灯总成, 适合各种款型摩托车车灯配套。
另外,利用上述 LED灯发光单元也可以形成汽车 LED前照灯,其包括 近光灯板、 远光灯板、 后壳和灯片。 近光灯板和远光灯板安装在后壳内, 灯片罩于近光灯板和远光灯板的出光面前方。
所述近光灯板由至少两个所述发光单元安装在一个灯架上构成,其中 发光单元中至少有二个是近光发光单元,并根据具体要求调节近光发光单 元的比例。近光灯板中多个近光发光单元的杯顶柱面可全部竖直排列,也 可一部分竖直排列,另一部分由竖直方向向顺时针方向旋转 1 ° 〜22° 排 列。
所述远光灯板也由至少两个所述发光单元安装在一个灯架上构成,其 中发光单元中至少有一个是远光发光单元,根据具体要求确定这种发光单 元的使用比例。
所述两灯板在灯壳中一上一下或左右方式布置安装,两者分成两个独 立的部分紧邻布置或者相互连接,或者也可以做成一整体。当近光灯板在 上远光灯板在下时,两灯板出光面的夹角保持在 16 1 ° 〜180° ; 当远光 灯板在上而近光灯板在下时, 两灯板出光面的夹角保持在 18 1 ° 〜200 ° ; 当两灯板为一左一右布置时,所述近光灯板的出光面较远光灯板的出 光面向下倾斜 1 ° 〜20° 。
再进一步, 利用上述的 LED灯发光单元还可以形成另一种形式的汽 车、 摩托车 LED前照灯, 这种前照灯包括 LED灯发光单元、 灯板、 灯座、 灯片和后壳和透明外罩;所述灯板及 LED灯发光单元安装在灯座内,灯片 安装于灯座或灯板上,并位于 LED灯发光单元出光面前方。所述灯座为散 热灯座, 由铝合金或铝做成。
所述灯板上并列布置有至少三个所述的 LED灯发光单元,其中至少有 一个 LED灯发光单元的出射光线与灯板平面的垂直线之间呈 0. 5° 〜22° 夹角,且与灯板平面的垂直线呈所述夹角的 LED灯发光单元中,至少有一 个 LED灯发光单元的杯顶表面有竖直排列的柱面 (包含阶梯面上分布柱面 的情况), 形成前照灯的近光部分; 所述灯架上其余的 LED灯发光单元的 杯顶表面为平面(包含阶梯面为平面的情况)或凹面, 同时, 至少有一个 LED灯发光单元的出射光线与灯板平面的垂直线重合,即 LED灯发光单元 的杯顶出光面与灯板平面一致, 形成前照灯的远光部分。
上述汽车或摩托车前照灯, 当单独启动近光部分时, 远光部分不亮。 近光部分由于向地面倾斜一定角度, 工作光照范围可以从车前轮延伸至 25m远, 形成高不过 0. 5m (明暗截止线右端从中心点向上旋转 0. 1 ° 〜 22° ),宽 8m的矩形主光斑,加两侧散射光,可在不直射对方来车前提下, 照亮前进路面及右侧行人。当启动远光部分时,其能集中形成水平出射光, 照亮远方行人、车辆、道路牌等。而且,本前照灯由于采用的是 LED光源, 所需功率不大,在远光灯工作时近光灯也可以同时工作,由此可将从汽车、 摩托车前轮至远方的位置都照亮,保证汽车、摩托车前方 25米内无黑斑, 照亮范围宽广, 更有利安全行驶。
综上所述,, 本发明具有以下显著的优点- 通过合理设计二次光学系统——即灯杯(透镜)的结构, 以及灯珠在 灯杯中的安装位置,使发光单元的出射光亮度和成型光斑均可以达到理想 的要求。 使用这种发光单元作为 LED汽车、 摩托车前照灯的光源, 较传 统的前照灯比较: 功率降低了 75%; 照度提高了一倍或多倍; 不发热, 而且 LED灯珠不怕水, 不怕摔环, 寿命可延长数倍; 可以实现开远光灯 时近光灯同时工作目标, 消除了安全隐患。
附图说明
图 1是一种 B型灯杯的发光单元的结构示意图 (双面凸透镜) 图 1A是 B型灯杯的发光单元的光路图
图 1AA是图 1A的杯顶局部柱面的光路图
图 1B是 B型灯杯的发光单元的俯视图
图 2是一种 B型灯杯的发光单元的结构示意图 (单面凸透镜) 图 2A是 B型灯杯的发光单元的光路图
图 2B是另一种 B型灯杯的发光单元的结构示意图(凹透镜、阶梯面) 图 2C是又一种 B型灯杯的发光单元的结构示意图(凹透镜、阶梯面) 图 3—种 A型灯杯的发光单元的结构示意图 (双面凸透镜) 图 3A是 A型灯杯的发光单元的光路图
图 4另一种 A型灯杯的发光单元的结构示意图 (双面凸透镜) 图 4A是 A型灯杯的发光单元的光路图
图 4B是另一种 A型灯杯的发光单元的结构示意图(凹透镜、阶梯面) 图 4C是又一种 A型灯杯的发光单元的结构示意图(凹透镜、阶梯面) 图 5是一种灯珠的光路图 (虚焦点和实焦点重合)
图 6是另一种灯珠的光路图 ((虚焦点和实焦点不重合)
图 7是一种形式的摩托车 LED前照灯光源的结构示意图
图 7A是图 7的侧视图;
图 8是一种形式的汽车 LED前照灯的外形图;
图 8A是图 7的 A- A剖面图;
图 9是前照灯中四种形式的近光灯板和远光灯板的布置图; 图 9A是第一种形式;
图 9B是图 7A的侧视图;
图 9C是第二种形式;
图 9D是第三种形式;
图 9E是第四种形式。
图 10是一种形式的摩托车 LED前照灯的外形图;
图 10A是图 7的 A- A剖面图;
图 11是第二形式的前照灯的平面布置图;
图 12是第三形式的前照灯的平面布置图。
具体实施方式
以下结合附图进一步详细说明本发明提出的发光单元以及汽车、 摩 托车前照组合灯的具体结构:
实施例 1: 发光单元
参见图 1和图 1A, 此发光单元是采用的 B型灯杯, 其由透镜式灯杯 15、 LED灯珠 12和电路板 11组成(一块电路板可安装多个透镜式灯杯和 LED灯珠, 形成多个发光单元)。 该灯杯采用透光率 92. 8%以上的 PMMA光 学材料注塑成型, 是一实心体透镜。 该灯杯的侧表面 14是由抛物线沿灯 杯轴向回转而形成的抛物反射面(当然也可以是由一段圆弧线沿灯杯轴向 回转而形成的球型反射面,或采用自由曲面)。在灯杯的杯座中心留有 LED 灯珠安装孔, LED灯珠安装孔的孔顶为双面凸透镜 16 (R1和 R2组成)结 构。 透镜式灯杯通过杯座固定在电路板 11上。 该灯杯的抛物反射面焦点 与双面凸透镜的焦点是重合的, 重合点位 A点。
LED灯珠 12采用一次光封成型的灯珠,参见图 5,其是单芯片灯珠, 发光芯片的尺寸选用 1毫米 X 1毫米。 该 LED灯珠 12安装在电路板 11 上, 并插入透镜式灯杯的杯座的 LED灯珠安装孔中, 灯杯的抛物反射面 与双面凸透镜的重合焦点正好落于 LED灯珠出射光的实焦点上 (该灯珠 的实焦点和虚焦点是重合的), 即 LED灯珠的发光芯片 13的位置与灯杯 的抛物反射面与双面凸透镜的焦点正好重合。 参见图 1A, 这样灯珠的发 光芯片 13发出的光经灯杯的抛物反射面反射和全反射, 而经灯杯凸透镜 透射的光可 "基本"沿光轴平行出射, 由此显著提高光的利用率。
该灯杯的杯顶是分布多条竖直排列并相互连续柱面 17, 光在灯杯顶 端经过多条柱面 17透镜射出的光如图 1AA所示,这些柱面透镜会将出射 光水平拉伸为一矩形光斑或近似于矩形(如椭圆形)光斑, 由此达到摩托 车前照灯所需要的近光效果。
图 2和图 2A所示的另一种采用 B型灯杯的发光单元的结构,其与图 1 的结构不一样的地方在于 LED灯珠安装孔的孔顶采用的是单面凸透镜 18, 其它结构相同, 也能达到前一种发光单元的发光效果。
图 2B和图 2C所示为另一种采用 B型灯杯的发光单元的结构, 其与 图 1的结构不一样的地方在于 LED灯珠安装孔的孔顶采用的是凹透镜 18', 杯顶为多圈向杯中心逐级降低的台阶,台阶面分布有柱面,其它结构相同, 也能达到前一种发光单元的发光效果。
图 3和图 3A、 图 4、 图 4A、 图 4B和图 4C所示的是采用 A型灯杯 灯杯的发光单元的结构,其与图 1和图 2的发光单元结构基本一样,只是 其杯顶采用的是平面或台阶平面, 由此产生不一样的出光效果,其灯珠发 出的光通过 A型灯杯的反射和透射形成的是圆形光斑。 由此达到摩托车 前照灯所需要的远光效果。
而对于灯珠,前面几种结构采用的是一种结构较特殊的灯珠, 即灯珠 出射光的实焦点和虚焦点是重合的。事实上,本发光单元可以采用其它任 何形式的灯珠, 如图 6所示, 该灯珠的出射光的实焦点 A (即发光芯片位 置)与虚焦点 B是不重合的。 采用该灯珠形成的发光单元如图 4和图 4A 所示,此结构中 LED灯珠 12位置设置是将灯杯的抛物反射面与双面凸透 镜的重合焦点落在 LED灯珠 12出射光的虚焦点上。当然实际装配中,也 可以将重合焦点落于发光中心即实焦点上,或者落于虚焦点和实焦点之间 的任意位置上, 这些都可以使发光单元获得理想的发光效果。
实施例 2: 摩托车 LED前照灯
采用上述发光单元形成的摩托车 LED前照灯光源参见图 7和图 7A, 所述光源包括近光灯板 3和远光灯板 2。
近光灯板 3 是在灯架上并排安装三个杯顶分布多条柱面的发光单元 1B构成。远光灯板 2是在灯架上并排安装 8个杯顶为平面的发光单元 1A 构。 当然, 根据需要, 近光灯板 3上也可以安装一定数量比例的发光单元 1B, 远光灯板 2上安装一定数量比例的发光单元 1A。
安装时,两灯板在灯壳中一上一下紧邻布置安装,近光灯板 3与远光 灯板 2出光面之间的夹角保持在 187° 。
前照灯的具体安装是将已焊好 LED灯珠的电路板对应前照灯各灯杯 (透镜)的杯底安装孔落座, 再与灯片、后壳组装成一体, 构成前照灯总 成。
实施例 3: 汽车 LED前照灯
采用上述发光单元形成的汽车 LED前照灯参见图 8和图 8A, 所述光 源包括近光灯板 2、 远光灯板 3、 后壳 6和灯片 4。 近光灯板 3和远光灯 板 2安装在后壳 6内,灯片 4罩于近光灯板和远光灯板的出光面前方。其 中远光灯板 2和近光灯板 3在后壳 6中一上一下紧邻布置安装,两灯板出 光面的夹角保持在 187° 。该前照灯的具体安装是将已焊好 LED灯珠的电 路板 8对应前照灯各灯杯的杯底安装孔落座, 形成各发光单元 1, 发光单 元 1固定在支撑架 7和支撑板 5上, 形成近光灯板 2和远光灯板 3, 再与 灯片 4、 后壳 6组装成一体, 即构成汽车前照灯。
远光灯板 2和近光灯板 3上的发光单元的布置有多种组合形式,参见 图 9, 具体如下:
如图 9A所示,近光灯板 3由 7个近光发光单元 1B并排安装在一个灯 架上构成, 其中发光单元中第 1、 3、 5、 7个近光发光单元的杯顶柱面是 竖直排列的, 第 2、 4、 6个近光发光单元的杯顶的柱面是由竖直方向向顺 时针方向旋转约 15° 排列布置的。远光灯板 2是由 14个远光发光单元 1A 分两排安装在一个灯架上构成。
如图 9B所示, 近光灯板 3由 5个近光发光单元 1B和两个远光发光 单元 1A并排安装在一个灯架上构成, 其中近光发光单元 1B设置在第 1、
2、 3、 6、 7位置, 第 1和第 7位置的近光发光单元的杯顶柱面是竖直排 列的,第 2、 4、 6位置近光发光单元的杯顶的柱面是由竖直方向向顺时针 方向旋转约 15° 排列布置的, 远光发光单元 1A则设置在第 3、 5位置。 远光灯板 2是由 14个发光单元分两排安装在一个灯架上构成, 其中第一 排 7个全部是远光发光单元 1A,第二排的第 3、 5位置是近光发光单元 1B, 其余为远光发光单元。
如图 9C所示,近光灯板 3由 7个近光发光单元 1B并排安装在一个灯 架上构成, 其中发光单元中第 1、 3、 5、 7个近光发光单元的杯顶柱面是 竖直排列的, 第 2、 4、 6个近光发光单元的杯顶的柱面是由竖直方向向顺 时针方向旋转约 15° 排列布置的。远光灯板 2是由 14个发光单元分两排 安装在一个灯架上构成, 其中第一排 7个全部是远光发光单元 1A, 第二 排的第 3、 5位置是近光发光单元 1B, 其余为远光发光单元。
如图 9D所示,近光灯板 3由 5个近光发光单元 1B和两个远光发光单 元 1A并排安装在一个灯架上构成, 其中近光发光单元 1B设置在第 1、 2、
3、 6、 7位置,第 1和第 7位置的近光发光单元的杯顶柱面是竖直排列的, 第 2、 4、 6位置近光发光单元的杯顶的柱面是由竖直方向向顺时针方向旋 转约 15 ° 排列布置的, 远光发光单元 1A则设置在第 3、 5位置。 远光灯 板 2是由 14个远光发光单元 1A分两排安装在一个灯架上构成。
以上实施例均是显示的近光和远光灯板上下布置的方式,而两灯板一 左一右布置也是常见的方式,此布置需要注意的是要将近光灯板的出光面 设置为较远光灯板的出光面向下倾斜 1 ° 〜20° 为宜。
实施例 4: 汽车 LED前照灯
采用上述 LED灯发光单元形成的另一种形式的汽车 LED前照灯,参见 图 10, 该前照灯包括 LED灯发光单元 1、灯板 9、灯座 10、灯片 4和后壳 6和透明外罩 11, 灯板 9安装在灯座 10内, LED灯发光单元 1安装在灯 板 9上(灯板 9上分布有与 LED灯发光单元大小对应的孔, LED灯发光单 元安装在孔中),灯片 4安装于灯座 10上,并位于 LED灯发光单元出光面 前方, 灯座 10装配在后壳 6内, 前方由透明外罩 11罩住。 灯座 10最好 采用铝合金散热灯座。
结合参见图 10A, 灯板 7上并列布置有五个 LED灯发光单元, 其中有 两个 LED灯发光单元形成近光部分 12, 它们的出射光线与灯板 9的灯板 平面的垂直线呈 4° 夹角,且这两个 LED灯发光单元的杯顶表面为竖直排 列的柱面形式。灯板上其余的三个 LED灯发光单元形成前照灯的远光部分 13,它们的杯顶表面为平面,并且这些 LED灯发光单元的出射光线与灯板 平面的垂直线重合, 即杯顶的出光面与灯板平面一致, 没有角度。
当然, LED灯发光单元在的布置形式有很多, 以下在例举两种, 但实 际不限于以下形式:
参见图 11 , 图中也是采用的五个 LED灯发光单元, 其中有两个 LED 灯发光单元形成近光部分 12, 它们的出射光线与灯板 9的灯板平面的垂 直线呈 0. 5° 〜22° 夹角, 但这两个 LED灯发光单元中, 只有一个的杯顶 表面为竖直排列的柱面形式,另一个为平面。灯板上其余的三个 LED灯发 光单元形成前照灯的远光部分 13, 它们的杯顶表面均为平面, 并且这些 LED灯发光单元的杯顶的出光面与灯板平面一致, 没有角度。
参见图 12, 图中也是采用的五个 LED灯发光单元, 其中有两个 LED 灯发光单元形成近光部分 12, 它们的出射光线与灯板 9的灯板平面的垂 直线呈 0. 5° 〜22 ° 夹角,这两个 LED灯发光单元的杯顶表面为竖直排列 的柱面形式,柱面比较密。灯板上其余的三个 LED灯发光单元形成前照灯 的远光部分 13, 这些 LED灯发光单元的杯顶的出光面与灯板平面一致, 没有角度。 它们的杯顶表面也为竖直排列的柱面形式, 但柱面比较稀疏, 即间距比较宽, 这种形式也可以达到远光效果。
以上前照灯中, LED灯发光单元的数量还可以根据需要而增加, 且近 光部分和远光部分的位置可以变化。但以上的前照灯在安装时,要保证近 光部分形成所述夹角而导致 LED灯发光单元的杯顶面的倾斜方向是相对 于远光部分的杯顶表面向下倾斜的。
以上实施例中, LED灯发光单元的杯顶最好采用图 2B、图 2C或图 4B、 图 4C的台阶形式, 这样可以减轻重量, 节省材料。
本发明的保护范围并不限于上述的实施例,显然,本领域的技术人员 可以对本发明进行各种改动和变形而不脱离本发明的范围和精神。倘若这 些改动和变形属于本发明权利要求及其等同技术的范围内,则本发明的意 图也包含这些改动和变形在内。

Claims

权 利 要 求 书
1、 一种 LED灯发光单元, 其由透镜式灯杯、 LED灯珠和电路板组 成 ·, 其特征在于:
所述透镜式灯杯是采用光学材料注塑成型的实心体,所述灯杯的侧表 面是由抛物线沿灯杯轴向回转而形成的抛物反射面,或是由一段圆弧线沿 灯杯轴向回转而形成的球型反射面, 或为自由曲面;
在所述灯杯的杯座中心留有 LED灯珠安装孔, LED灯珠安装孔的孔 顶为双面凸透镜、 单面凸透镜或凹透镜结构;
所述灯杯的抛物反射面或球型反射面或自由曲面的焦点与双面凸透 镜、 单面凸透镜或凹透镜的焦点重合;
所述 LED灯珠安装在电路板上,并插入透镜式灯杯的杯座的 LED灯 珠安装孔中,并使灯杯的抛物反射面或球型反射面或自由曲面与双面凸透 镜或单面凸透镜或凹透镜的重合焦点落于 LED灯珠发光中心即实焦点与 虚焦点之间,或者落于所述实焦点上,或者落于所述虚焦点上;所述 LED 灯珠出射光的实焦点即为 LED灯珠的发光芯片位置或荧光粉层位置; 所 述透镜式灯杯通过杯座固定在电路板上;
2、 根据权利要求 1所述的发光单元, 其特征在于: 所述灯杯的杯顶 为一整平面,或者杯顶为分布至少一条竖直排列的柱面;或者杯顶中心下 凹形成双面凸透镜的一个面或平面,杯顶的其余部分为平面或分布至少一 条竖直排列的柱面;或者杯顶为多圈向杯中心逐级降低的台阶, 台阶面为 平面或分布有柱面。
3、 利用权利要求 1或 2所述的 LED灯发光单元形成的汽车 LED前照 灯, 所述前照灯包括近光灯板、远光灯板、灯壳和灯片; 所述近光灯板和 远光灯板安装在灯壳内, 灯片罩于近光灯板和远光灯板的出光面前方; 所述近光灯板和远光灯板在灯壳中一上一下或一左一右布置安装,两 者相互紧邻、 相互连接或为一整体;
所述近光灯板至少由两个所述 LED灯发光单元安装在一个灯架上构 成,其中 LED灯发光单元中至少有两个近光发光单元;所述近光发光单元 的灯杯的杯顶分布至少一条竖直排列的柱面;或者杯顶中心下凹致形成双 面凸透镜的一面或平面或凹面,杯顶分布有至少一条竖直排列的柱面;或 杯顶为多圈向杯中心逐级降低的台阶, 台阶面上分布有柱面;
所述远光灯板至少也由两个 LED灯发光单元安装在一个灯架上构成, 其中 LED灯发光单元中至少有一个为远光发光单元;所述远光发光单元的 灯杯的杯顶为一整平面或凹面, 或者杯顶为多圈向杯中心逐级降低的台 阶, 台阶面为平面。
4、 根据权利要求 3所述的汽车 LED前照灯, 其特征在于, 所述近光 灯板上的近光发光单元按照其杯顶的柱面竖直排列的方式布置,或按一个 或一部分近光发光单元的杯顶的柱面竖直排列,而其余的近光发光单元的 杯顶的柱面由竖直方向向顺时针方向旋转 1 ° 〜22° 排列的方式布置。
5、 根据权利要求 3或 4所述的汽车 LED前照灯, 其特征在于, 当所 述近光灯板在上方远光灯板在下方时,所述近光灯板与远光灯板的出光面 夹角保持在 16 1 ° 〜180° ;当远光灯板在上而近光灯板在下时,两灯板 的出光面夹角保持在 18 1 ° 〜200° ; 当两灯板为一左一右布置时,所述 近光灯板的出光面较远光灯板的出光面向下倾斜 1 ° 〜20° 。
6、利用权利要求 1或 2所述的 LED灯发光单元形成的汽车、摩托车 LED前照灯, 所述前照灯包括 LED灯发光单元、 灯板、 灯座、 后壳和透明 外罩;所述灯板及 LED灯发光单元安装并定位在灯座内,灯座前方由透明 外罩罩住;所述灯板上并列布置有至少三个所述的 LED灯发光单元,其中 至少有一个 LED 灯发光单元的出射光线与灯板平面的垂直线之间呈 0. 5 ° 〜22° 夹角, 且与灯板平面的垂直线呈所述夹角的 LED灯发光单元中, 至少有一个 LED灯发光单元的杯顶表面为竖直排列的柱面形式,形成前照 灯的近光部分;所述灯架上其余的 LED灯发光单元的杯顶表面为平面或凹 面, 同时,至少有一个 LED灯发光单元的出射光线与灯板平面的垂直线重 合,即 LED灯发光单元的杯顶出光面与灯板平面一致,形成前照灯的远光 部分。
7、 根据权利要求 6所述的汽车、 摩托车 LED前照灯, 其特征在于: 所述灯座为铝合金或铝散热灯座。
8、 根据权利要求 6所述的汽车、 摩托车 LED前照灯, 其特征在于: 还包括有灯片,灯片安装于灯座或灯板上,并位于 LED灯发光单元出光面 刖万。
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* Cited by examiner, † Cited by third party
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JP2015509653A (ja) * 2012-03-08 2015-03-30 コーニンクレッカ フィリップス エヌ ヴェ 可動光源を有する制御可能な高輝度照明
JP2014167879A (ja) * 2013-02-28 2014-09-11 Koito Mfg Co Ltd 車両用灯具
EP3767166B1 (en) 2018-03-16 2021-09-29 Antares Iluminación, S.A.U. Optical system

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