Carrier of one or more light-emitting diodes (LEDS) for a signaling module

• US 10,246,001 B2
• Filed: 07/29/2015
• Issued: 04/02/2019
• Est. Priority Date: 07/31/2014
• Status: Active Grant

• Current Assignee: Valeo Vision (Valeo SE)
• Original Assignee: Valeo Vision (Valeo SE)
• Inventors: Lauvernier, Denis, Zojceski, Zdravko
• Primary Examiner(s): Bowman, Mary Ellen
• Application Number:
  US14/812,217
• Publication Number:
  US 20160031361A1
• Time in Patent Office: 1,343 Days
• CPC Class Codes: B60Q 1/0088 Details of electrical connections B60Q1/305 takes precedence; electrical connection of the light source itself F21S41/192, F21S43/195
• CPC Class Codes: B60Q 1/2696 Mounting of devices using LEDs
• CPC Class Codes: F21S 43/14 Light emitting diodes [LED]
• CPC Class Codes: F21S 43/19 Attachment of light sources or lamp holders
• CPC Class Codes: F21S 43/195 Details of lamp holders, terminals or connectors
• CPC Class Codes: F21Y 2107/00 Light sources with three-dimensionally disposed light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05K 1/0284 Details of three-dimensional rigid printed circuit boards H05K1/119 takes precedence; shaping of the substrate H05K3/0014
• CPC Class Codes: H05K 1/184 Components including terminals inserted in holes through the printed circuit board and connected to printed contacts on the walls of the holes or at the edges thereof or protruding over or into the holes
• CPC Class Codes: H05K 2201/0129 Thermoplastic polymer, e.g. auto-adhesive layer; Shaping of thermoplastic polymer
• CPC Class Codes: H05K 2201/09118 Moulded substrate
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 3/185 by making a catalytic pattern by photo-imaging

Abstract

A carrier of one or more light sources for a lighting and/or signaling module especially for an automotive vehicle, comprising: a substrate having at least one aperture and electrical tracks on at least one side; and at least one light-emitting diode (LED) having a body and electrical connection leads lateral to the body. The LED or at least one of the LEDs is placed through a respective aperture of the substrate, and the connection leads make contact with respective electrical tracks. The substrate is a rigid molded part having a three-dimensional shape possibly providing an optical function such as that of a reflector. In this case, the LEDs are directly supported by the optical part.

Claims

1. A carrier of one or more light sources for a luminous module for an automotive vehicle, comprising:

a substrate that is rigid and has at least one aperture and electrical tracks on at least one side; and

at least one or more light-emitting diodes (LEDs), each of said at least one or more LEDs having a body and electrical connection leads lateral to said body, said at least one or more LEDs being placed through said at least one aperture of said substrate, said electrical connection leads making contact with respective said electrical tracks;

wherein said substrate is a rigid molded part having a three-dimensional shape,

wherein a material of said substrate is a thermoplastic doped with conductive metal particles and is configured to adhere to said electrical tracks, and

wherein an optical portion of said at least one or more LEDs extends beyond an opposite surface of said substrate from said at least one side of said substrate with said electrical tracks.

2. The carrier according to claim 1, wherein said substrate forms a wall having over its extent variations in height of more than 10% of its extent.

3. The carrier according to claim 1, wherein said substrate has one or more cavity- and/or step-shaped portions.

4. The carrier according to claim 1, wherein said electrical connection leads of said at least one or more LEDs are connected to respective electrical tracks by a polymer adhesive filled with metal particles, said polymer adhesive configured to polymerize after application.

5. The carrier according to claim 1, wherein said electrical connection leads of said at least one or more LEDs are connected to respective electrical tracks by a metal, said metal being deposited by a chemical metalization process.

6. The carrier according to claim 1, wherein said carrier comprises a connector integrally formed with said substrate.

7. The carrier according to claim 1, wherein said substrate comprises at least one electronic component connected electrically to said at least one or more LEDs by said electrical tracks.

8. The carrier according to claim 1, wherein said substrate has at least one surface interacting with light rays emitted by said at least one or more LEDs to provide an optical function.

9. The carrier according to claim 8, wherein said at least one surface of said substrate, interacting with the light rays, is reflective, absorbent or scattering.

10. The carrier according to claim 8, wherein said substrate comprises a reflective, absorbent or scattering coating on its side opposite that of said electrical tracks.

11. A signaling module comprising:

a carrier of one or more light sources; and

an optical part, interacting with light rays emitted by said one or more light sources;

wherein said carrier is according to claim 1.

12. The signaling module according to claim 11, wherein said carrier comprises said optical part and said carrier forms said optical part.

13. A lighting and/or signaling device comprising:

a housing;

a luminous module disposed in said housing; and

an outer lens placed on said housing;

wherein said luminous module is a signaling module according to claim 11.

14. The carrier according to claim 2, wherein said substrate has one or more cavity- and/or step-shaped portions.

15. The carrier according to claim 2, wherein said electrical connection leads of said at least one or more LEDs are connected to respective electrical tracks by an adhesive filled with metal particles, said adhesive being a polymer adhesive configured to polymerize after application.

16. The carrier according to claim 3, wherein said electrical connection leads of said at least one or more LEDs are connected to respective electrical tracks by an adhesive filled with metal particles, said adhesive being a polymer adhesive configured to polymerize after application.

17. A lighting and/or signaling device, comprising:

a housing;

a luminous module disposed in said housing; and

an outer lens placed on said housing;

wherein said luminous module is a signaling module according to claim 12.

18. The signaling module of claim 11, wherein said optical part comprising a reflector.

19. A signaling module comprising:

a carrier of one or more light sources; and

an optical part, interacting with light rays emitted by said one or more light sources;

wherein said carrier is according to claim 3.

20. The carrier according to claim 5, wherein said metal is copper.

21. The carrier according to claim 1, wherein said electrical connection leads of said at least one or more LEDs are step-shaped to mechanically connect to said electrical tracks.

22. The carrier according to claim 21, wherein said electrical connection leads of said at least one or more LEDs are also connected to said electrical tracks with a metal-doped adhesive.