Patent Publication Number: US-10788181-B1

Title: LED automobile lamp

Description:
CROSS REFERENCE TO THE RELATED APPLICATIONS 
     This application is based upon and claims priority to Chinese Patent Application No. 2019108920936, filed on Sep. 20, 2019, the entire contents of which are incorporated herein by reference. 
     TECHNICAL FIELD 
     The present disclosure relates to the technical field of electric light source, and more particularly, to an LED automobile lamp. 
     BACKGROUND 
     Currently, LED automobile lamps generally have the following disadvantages.
         1. During the product assembly processes, homogeneity of an LED automobile lamp is poor due to fitting installation errors. A large proportion of mass-produced automobile lamps cannot meet regulatory requirements, and a necessary percentage of automobile lamps passing inspection cannot be guaranteed unless a full product inspection and a subsequent calibration are made.   2. High luminous efficacy, long service life and high reliability of the LED, can all be expected in theory, however, these features are not guaranteed in practice and the LED may even display early failure because of a poor design for thermal conduction and poor reliability of the LED.   3. An unreasonable, incompetent or insufficient heat dissipation design may lead to adverse consequences regarding the operating junction temperature of the LED that may reach beyond a safe temperature range. High luminous efficacy, long service life, and high reliability of the LED which are possible to achieve in theory, cannot be guaranteed and even early failure of the LED is possible in practice.   4. The light distribution of the LED cannot meet the regulatory requirements, and the lighting safety and comfort expected from an operational LED automobile lamp cannot be guaranteed because of the LED structural design not being an optically sound design, or having a light distribution design method that is not reasonable.       

     SUMMARY 
     An objective of the present disclosure is to solve the problems in the prior art by providing an LED automobile lamp, which can ensure homogeneity of mass-produced products and has a high luminous efficacy, long service life, and high reliability. 
     To achieve the above objective, the present disclosure provides an LED automobile lamp, that includes a lens, a heat dissipation shell, a light source pillar, and a rear cover. The heat dissipation shell is internally mounted with a light-reflecting surface, the light source pillar is installed at the bottom of the heat dissipation shell, the lens is mounted at the top of the heat dissipation shell, and the rear cover is mounted at the bottom of the light source pillar. A first light source plate and a second light source plate are symmetrically mounted on two sides of the light source pillar. Both the first light source plate and the second light source plate extend into a light-reflecting region surrounded by the light-reflecting surface and the lens. The top of the light source pillar is provided with a light-shielding sheet, and the bottom of the light source pillar is provided with a stepped plane closely coupling with the heat dissipation shell. 
     Preferably, the light source pillar is tightly fastened to the heat dissipation shell by a plurality of screws, and the light source pillar further includes a fixed pillar body and a stepped limit dais. Two sides of the fixed pillar body are symmetrically provided with flat mounting surfaces for fixing the first light source plate and the second light source plate. A plurality of second mounting holes are uniformly arranged on the flat mounting surface. The light-shielding sheet is arranged on the top of the fixed pillar body, the stepped limit dais is arranged on the bottom of the fixed pillar body, and the stepped plane is arranged on the end face where the stepped limit dais is connected to the fixed pillar body. 
     Preferably, the bottom of the heat dissipation shell is provided with a cylindrical boss, wherein the cylindrical boss is internally provided with a stepped circular hole fitting with the light source pillar. A plurality of guide positioning grooves with different sizes are arranged at intervals in a circumferential direction of the stepped limit dais, and the stepped circular hole of the cylindrical boss is internally provided with a plurality of guided anti-deviation ribs protruding inwardly and fitting together with the guide positioning grooves. 
     Preferably, the light-reflecting surface is an integrated structure or a combined structure. 
     Preferably, the light-reflecting surface is composed of two semi-light-reflecting surfaces and a transition surface connected between the two semi-light-reflecting surfaces. The two semi-light-reflecting surfaces are respectively arranged in correspondence with the first light source plate and the second light source plate. The focus of each of the two semi-light-reflecting surfaces is located on the surface of the corresponding light source plate. The transition surface does not participate in light distribution. 
     Preferably, the outer surface of the heat dissipation shell is provided with a heat dissipation fin, the heat dissipation fin is consistent with a vertical mounting direction of the automobile lamp, and the heat dissipation shell is made of aluminum alloy material. 
     Preferably, the light-reflecting surface is arranged on a concave surface of a light-reflecting component, and a support hem is extended on an outer periphery of the light-reflecting component. A plurality of fixed mounting studs is arranged at intervals in the heat dissipation shell, and the support hem is provided with first mounting holes corresponding to the fixed mounting studs. 
     Preferably, the rear cover is tightly fastened to the cylindrical boss at the bottom of the heat dissipation shell by screws, the rear cover is provided with an integrally-injected power copper pin, the rear cover is internally provided with a round hole for potting, and the rear cover is also provided with a nylon rivet for hole sealing. 
     Preferably, when the light-reflecting surface independently distributes light, the lens is a flat transparent lens; and when the light-reflecting surface distributes light in combination with the lens, the lens is a pattern lens. 
     Preferably, a cross-sectional shape of the light-reflecting surface is approximate to a circle or a rectangle. When the cross-sectional shape of the light-reflecting surface is a rectangle, an auxiliary light-shielding sheet is also arranged at an end of the light source pillar, and an end of the auxiliary light-shielding sheet has a light-shielding hem extending toward the light source plate. 
     The advantages of the present disclosure are listed below. The present disclosure provides a new-type of LED automobile lamp structure and a light distribution design to eliminate installation error of attachments and ensure homogeneity of mass-produced products. Based on an optimized design of heat conduction and heat dissipation, it is ensured that an operating junction temperature of the LED is relatively low and within a safe range, and it is ensured that the LED automobile lamp has a theoretically high luminous efficacy, long service life, and highly reliable. The light distribution design combined with a structural design can simplify the light distribution design and make it easier to comply with regulatory requirements so as to ensure the safety and comfort of automobile lamp lighting. 
     Features and advantages of the present disclosure will be described in detail through embodiments with reference to accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded view of the LED automobile lamp according to Embodiment 1 of the present disclosure; 
         FIG. 2  is an exploded view of the heat dissipation shell of the LED automobile lamp according to Embodiment 1 of the present disclosure; 
         FIG. 3  is an exploded view of the light source pillar of the LED automobile lamp according to Embodiment 1 of the present disclosure; 
         FIG. 4  is an exploded view of the rear cover of the LED automobile lamp according to Embodiment 1 of the present disclosure; 
         FIG. 5  is an exploded view of the LED automobile lamp according to Embodiment 2 of the present disclosure; 
         FIG. 6  is an exploded view of the light source pillar of the LED automobile lamp according to Embodiment 2 of the present disclosure; and 
         FIG. 7  is an exploded view of the LED automobile lamp according to Embodiment 3 of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     Embodiment 1 
     Referring to  FIG. 1 , an LED automobile lamp of the present disclosure includes the lens  1 , the heat dissipation shell  2 , the light source pillar  3 , and the rear cover  4 . The heat dissipation shell  2  is internally mounted with the light-reflecting surface  21 , the light source pillar  3  is mounted at the bottom of the heat dissipation shell  2 , the lens  1  is installed at the top of the heat dissipation shell  2 , and the rear cover  4  is mounted at the bottom of the light source pillar  3 . The first light source plate  31  and the second light source plate  32  are symmetrically mounted on two sides of the light source pillar  3 . Both the first light source plate  31  and the second light source plate  32  extend into the light-reflecting region surrounded by the light-reflecting surface  21  and the lens  1 . The top of the light source pillar  3  is provided with the light-shielding sheet  33 , and the bottom of the light source pillar  3  is provided with the stepped plane  34  closely coupling with the heat dissipation shell  2 . 
     Further, referring to  FIG. 3 , the light source pillar  3  is tightly fastened to the heat dissipation shell  2  by a plurality of screws, and the light source pillar  3  further includes the fixed pillar body  310  and the stepped limit dais  320 . Two sides of the fixed pillar body  310  are symmetrically provided with flat mounting surfaces  311  for fixing the first light source plate  31  and the second light source plate  32 . A plurality of second mounting holes are uniformly arranged on the flat mounting surface  311 . The light-shielding sheet  33  is arranged on the top of the fixed pillar body  310  to prevent the LED from directly emitting light. 
     Further, referring to  FIG. 3 , the stepped limit dais  320  is arranged on the bottom of the fixed pillar body  310 , and the stepped plane  34  is arranged on the end face where the stepped limit dais  320  is connected to the fixed pillar body  310 . The bottom of the heat dissipation shell  2  is provided with the cylindrical boss  22 , wherein the cylindrical boss  22  is internally provided with a stepped circular hole fitting with the light source pillar  3 . Three guide positioning grooves  35  with different sizes are arranged at intervals in a circumferential direction of the stepped limit dais  320 , and the stepped circular hole of the cylindrical boss  22  is internally provided with a plurality of guided anti-deviation ribs protruding inwardly and fitting with the guide positioning grooves  35 . This structure can prevent the light source pillar  3  from being mounted upside down or being mounted on a bias, and can ensure homogeneity of mass-produced products. 
     Further, referring to  FIG. 2 , as a combined structure, the light-reflecting surface  21  is composed of two semi-light-reflecting surfaces and a transition surface connected between the two semi-light-reflecting surfaces. The two semi-light-reflecting surfaces are respectively arranged by corresponding to the first light source plate  31  and the second light source plate  32 , and the focus of each of the two semi-light-reflecting surfaces is located on the surface of the corresponding light source plate. The transition surface does not participate in the light distribution. 
     Further, the outer surface of the heat dissipation shell  2  is provided with the heat dissipation fin  23 , and the heat dissipation fin  23  is distributed in a direction perpendicular to the direction in which the automobile lamp is mounted. The heat dissipation shell  2  is made of aluminum alloy material, and thus has a good thermal conductivity. 
     Further, the light-reflecting surface  21  is arranged on a concave surface of a light-reflecting component, and the support hem  210  is extended on the outer periphery of the light-reflecting component. A plurality of fixed mounting studs  20  are arranged at intervals in the heat dissipation shell  2 , and the support hem  210  is provided with first mounting holes corresponding to the fixed mounting studs  20 , facilitating installation and fixation. 
     Further, referring to  FIG. 4 , the rear cover  4  is tightly fastened to the cylindrical boss  22  at the bottom of the heat dissipation shell  2  by screws, the rear cover  4  is provided with the integrally-injected power copper pin  41 , the rear cover  4  is internally provided with the round hole  43  for potting thermally conductive waterproof glue, and the rear cover  4  is also provided with the nylon rivet  42  for hole sealing upon completion of glue potting. 
     Furthermore, when a cross-sectional shape of the light-reflecting surface  21  is a circle, and when the light-reflecting surface  21  independently distributes light, a flat transparent lens is selected as the lens  1 . 
     Embodiment 2 
     Referring to  FIG. 5  and  FIG. 6 , the differences between the present embodiment and Embodiment 1 are that the cross-sectional shape of the light-reflecting surface  21  is approximate to a rectangle, the auxiliary light-shielding sheet  36  is also arranged at an end of the light source pillar  3 , and an end of the auxiliary light-shielding sheet  36  has a light-shielding hem extending toward the light source plate, wherein the auxiliary light-shielding sheet  36  is mounted in a direction where a light-shielding portion is down from the mounting location of the automobile lamp. 
     Embodiment 3 
     Referring to  FIG. 7 , the differences between the present embodiment and Embodiment 1 are that the cross-sectional shape of the light-reflecting surface  21  is approximate to a rectangle, the light-reflecting surface  21  adopts an integrated structure, the light-reflecting surface  21  distributes light in combination with lens  1 , and a pattern lens is selected as lens  1 . 
     The above embodiments are for illustrating the present disclosure rather than limiting the present disclosure, and any solution obtained by simply modifying the present disclosure shall fall within the scope of protection of the present disclosure.