CN103363320A - Led lamp and manufacturing method thereof - Google Patents

Abstract

An LED lamp comprises an upper shell, a lens, a driving circuit board and an LED; the upper shell is provided with an accommodating groove, and the bottom of the accommodating groove is provided with a light hole; the lens is accommodated in the accommodating groove and covers the light hole; the lower shell is provided with an electric device groove, and one side of the lower shell, close to the opening of the electric device groove, is fixedly connected with one side of the upper shell, close to the light hole; the driving circuit board is accommodated in the motor groove; the LED is directly fixed on the driving circuit board and is opposite to the position of the light hole; the upper shell and the lens are respectively made of two plastic materials with similar molecular structures, and the lens is made of transparent plastic; the lens is directly fused and connected with the side wall of the containing groove of the upper shell in an ultrasonic welding mode so as to seal the opening of the containing groove. The upper shell and the lens of the LED lamp avoid the adoption of rubber sealing parts which are easy to age after insolation, so that the LED lamp is used for a long time, and particularly has better sealing property when being used outdoors. The invention further provides a manufacturing method of the LED lamp.

Description

LED lamp and manufacturing method thereof

【Technical field】

The invention relates to a lamp, in particular to an LED lamp and a manufacturing method thereof.

【Background technique】

At present, there is often a mechanical fit between the shell and the transparent part of the lamp. At the same time, the separate design of the reflector and the transparent part brings about an increase in materials, so that the fit between the lamps often affects the reliability of the entire lamp. Once the fit fails, the inside of the lamp The entry of dust, gas, liquid and other objects will cause problems such as internal corrosion of the lamps, which will lead to lighting failure of the lamps, safety accidents and other problems, bringing huge losses to the market and customers. This problem often requires the designer to spend a lot of time and energy to solve it, and sometimes even re-mold the mold in order to achieve the purpose of sealing the joint.

Please refer to Fig. 1, a traditional LED lamp 10 includes an upper shell 11, a lower shell 12, a reflector 13, a transparent member 14 and a rubber seal 15, and the upper shell 11 and the lower shell 12 are fixedly connected together through threaded fit, and together A receiving cavity (not shown in the figure) is formed. The upper shell 11 is provided with a light exit hole corresponding to the receiving cavity. Both the reflector 13 and the transparent member 14 are accommodated in the receiving cavity, wherein the transparent member 14 is disposed close to the light exit hole of the upper shell 11 . The rubber seal 15 covers the periphery of the light outlet of the reflector 13 and abuts between the transparent member 14 and the lower shell 12 . When the lamp 10 is used outdoors, since sunlight penetrates the transparent member 14 and irradiates the rubber seal 15 for a long time, the rubber seal 15 ages faster, resulting in poor sealing performance of the LED lamp 10 .

【Content of invention】

In view of the above situation, it is necessary to provide an LED lamp with better airtightness and a manufacturing method thereof.

An LED lamp, comprising:

The upper shell has a receiving tank, and the bottom of the receiving tank is provided with a light-transmitting hole;

a lens, housed in the receiving groove and covering the light-transmitting hole;

The lower case has an electrical slot, and the side of the lower case near the opening of the electrical slot is fixedly connected with the side of the upper case near the light-transmitting hole, so that the light-transmitting hole is connected to the The electrical slots are connected;

The driving circuit board is accommodated in the electrical appliance slot and arranged correspondingly to the light-transmitting hole; and

LEDs are directly fixed on the driving circuit board and housed in the light-transmitting holes;

Wherein, the upper case and the lens are respectively made of two plastic materials with similar molecular structures, and the lens is made of transparent plastic; The walls are fused together to seal the opening of the receiving tank.

In one of the embodiments, a fixing column is provided at the bottom of the electrical appliance slot, and the driving circuit board is fixed on the fixing column.

In one of the embodiments, the end surface of the free end of the fixing column is provided with a positioning boss, and the driving circuit board is provided with a positioning hole through which the positioning boss passes.

In one of the embodiments, a positioning post is provided on the side of the upper case close to the light-transmitting hole, and a corresponding opening is provided on the side of the lower case near the opening of the electrical appliance slot to accommodate the positioning post. Locating slot.

In one of the embodiments, the positioning post is provided with a screw hole on the end surface of its free end, and the bottom of the positioning groove is provided with a through hole for threaded fasteners to pass through, and the threaded fasteners and the positioning post The screw holes are screwed together to securely connect the upper shell and the lower shell.

In one of the embodiments, the positioning column is ring-shaped, and the positioning groove is a ring-shaped groove; the lamp further includes a sealing ring, and the sealing ring is accommodated in the positioning groove and is close to the inner side of the positioning groove Setting; the end surface of the free end of the positioning column abuts against the sealing ring.

In one of the embodiments, the lens has an arc-shaped light-emitting surface, and the arc-shaped light-emitting surface protrudes outside the upper shell.

In one embodiment, a boss is formed on the side of the lens opposite to the arc-shaped light-emitting surface, and the boss is accommodated in the light-transmitting hole.

In one of the embodiments, the bottom of the electric appliance slot is further provided with a supporting column for supporting the middle part of the driving circuit board.

A method for manufacturing an LED lamp, comprising the steps of:

providing an upper jig head and a lower jig head opposite to the upper jig head, the upper jig head is used to clamp the lens, and the lower jig head is used to clamp the upper shell;

The upper jig head moves toward the lower jig head until the lens is accommodated in the receiving groove of the upper case; and

Ultrasonic waves are used to irradiate the contact point between the lens and the side wall of the upper case storage groove, so that the contact point between the lens and the side wall of the upper case storage groove is welded together.

The upper shell and the lens of the above-mentioned LED lamps are made of two plastic materials with similar molecular structures, and are welded together by ultrasonic welding, avoiding the use of rubber seals that are prone to aging after exposure to the sun, so that the above-mentioned LED lamps can be used for a long time, especially It is better sealed when used outdoors.

【Description of drawings】

FIG. 1 is a cross-sectional view of a traditional LED lamp;

2 is a perspective view of an LED lamp according to an embodiment of the present invention;

Fig. 3 is a sectional view of the LED lamp shown in Fig. 2;

4 is a flow chart of a method for manufacturing an LED lamp according to an embodiment of the present invention;

FIG. 5 is a schematic structural view of the lens and the upper case of the LED lamp fixedly connected by the manufacturing method of the LED lamp shown in FIG. 4 .

【Detailed ways】

In order to facilitate the understanding of the present invention, the present invention will be described more fully below with reference to the associated drawings. Preferred embodiments of the invention are shown in the accompanying drawings. However, the present invention can be embodied in many different forms and is not limited to the embodiments described herein. On the contrary, these embodiments are provided to make the understanding of the disclosure of the present invention more thorough and comprehensive.

It should be noted that when an element is referred to as being “fixed” to another element, it can be directly on the other element or there can also be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or intervening elements may also be present. The terms "vertical," "horizontal," "left," "right," and similar expressions are used herein for purposes of illustration only.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the technical field of the invention. The terms used herein in the description of the present invention are for the purpose of describing specific embodiments only, and are not intended to limit the present invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

Referring to FIG. 2 and FIG. 3 , the LED lamp 100 according to the embodiment of the present invention includes an upper case 110 , a lens 120 , a lower case 130 , a driving circuit board 140 , an LED 150 and a sealing ring 160 .

The upper case 110 has a receiving slot 111 . A light-transmitting hole 113 is defined at the bottom of the receiving tank 111 . A positioning post 115 is disposed on a side of the upper shell 110 close to the light transmission hole 113 . The positioning post 115 defines a screw hole (not shown in the figure) on the end face of its free end. Specifically, in this embodiment, the positioning post 115 is ring-shaped, that is, the positioning post 115 surrounds the light transmission hole 113 for a circle.

The lens 120 is accommodated in the receiving groove 111 of the upper case 110 and covers the light transmission hole 113 . Specifically in this embodiment, the lens 120 has an arc-shaped light-emitting surface 121. When the lens 120 is installed in the receiving groove 111 of the upper case 110, the arc-shaped light-emitting surface 121 protrudes outside the upper case 110, so that the LED 150 emits light. The light is guided out of the upper shell 110 to increase the illumination brightness of the LED lamp 100 . A boss 123 is formed on a side of the lens 120 opposite to the arc-shaped light-emitting surface 121 , and the boss 123 is accommodated in the light-transmitting hole 113 of the upper case 110 .

Wherein, the upper shell 110 and the lens 120 are respectively made of two plastic materials with similar molecular structures, and the lens 120 is made of transparent plastic. The lens 120 is directly fused with the sidewall of the receiving tank 111 of the upper case 110 by ultrasonic welding, so as to seal the opening of the receiving tank 111 .

The lower case 130 has an electric appliance slot 131 . The side of the lower case 130 close to the opening of the electrical slot 131 is fixedly connected to the side of the upper case 110 near the light-transmitting hole 113, so that the light-transmitting hole 113 of the upper case 110 communicates with the electrical slot 131 of the lower case 130, For example, the lower shell 130 can be fixedly connected with the upper shell 110 by means of screw connection, welding, snap-fit connection and the like. Specifically, in this embodiment, both the upper shell 110 and the lower shell 130 are circular shells, so as to form a roughly round pie-shaped lamp structure.

The lower shell 130 is provided with a fixing column 133 and a supporting column 135 at the bottom of the electrical appliance slot 131 . The driving circuit board 140 is fixed on the fixing column 133. Specifically, the free end of the fixing column 133 is provided with a positioning boss 137, and the driving circuit board 140 is provided with a positioning hole (not shown) for the positioning boss 137 to pass through. The support column 135 is used to support the middle of the driving circuit board 140 . Specifically, in this embodiment, in order to improve the airtightness of the electrical appliance slot 131 after being sealed, the fixing post 133 is a circular cylinder, and there are a plurality of positioning bosses 137 arranged on the end surface of the free end of the fixing post 133 at intervals.

The side of the lower case 130 close to the opening of the electrical appliance slot 131 is correspondingly defined with a positioning slot 138 for accommodating the positioning post 115 of the upper case 110 . Specifically in this embodiment, the bottom of the positioning groove 138 is provided with a through hole (not marked) for threaded fasteners (not marked) to pass through, and the threaded fasteners and the screw holes of the positioning column 115 of the upper shell 110 The upper shell 110 and the lower shell 120 are fixedly connected by screwing together. When the positioning post 115 is ring-shaped, the positioning groove 138 is a ring-shaped groove, that is, the positioning groove 138 surrounds the fixing post 133 for a week.

The driving circuit board 140 is accommodated in the electrical slot 131 of the lower case 130 and is disposed corresponding to the light transmission hole 113 of the upper case 110 .

The LED 150 is directly fixed on the driving circuit board 140, and is accommodated in the light transmission hole 113 of the upper case 110. There can be multiple LEDs 150, which can be arranged in a circular ring or a rectangular array.

The sealing ring 160 is accommodated in the positioning groove 138 of the lower case 130 and disposed close to the inner side of the positioning groove 138 , that is, the sealing ring 160 is disposed close to the fixing post 133 of the lower case 130 . The end surface of the free end of the positioning column 115 of the upper case 110 abuts against the sealing ring 160 to seal and form a sealed cavity for accommodating the driving circuit board 140 .

It should be noted that both the upper shell 110 and the lower shell 130 can be made of plastic with poor translucency, so as to prevent the sealing ring 160 from easily aging when the LED lamp 100 is used outdoors.

The upper shell 110 and the lens 120 of the above-mentioned LED lamp 100 are respectively made of two plastic materials with similar molecular structures, and are welded together by ultrasonic welding, avoiding the use of rubber seals that are prone to aging after exposure to sunlight, so that the above-mentioned LED lamp 100 Long-term use, especially when used outdoors, the sealing is better.

Please refer to FIG. 4 and FIG. 5 , the manufacturing method of the LED lamp according to the embodiment of the present invention is used to manufacture the above-mentioned LED lamp 100, and the method includes steps S201-S203:

Step S201 , providing an upper jig head 210 and a lower jig head 220 opposite to the upper jig head 210 , the upper jig head 210 is used to clamp the lens 120 , and the lower jig head 220 is used to clamp the upper case 110 .

Step S202 , the upper jig head 210 moves toward the lower jig head 220 until the lens 120 is accommodated in the receiving groove of the upper shell 110 .

Step S203 , irradiating the contact portion between the lens 120 and the side wall of the receiving groove 111 of the upper case 110 with ultrasonic waves, so that the contact portion between the lens 120 and the side wall of the receiving groove 111 of the upper case 110 is welded together.

It should be noted that the longer the length of the fusion between the lens 120 and the side wall of the receiving groove 111 of the upper case 110 , the stronger the strength of the connection between the lens 120 and the upper case 110 .

When ultrasonic welding is used to weld thermoplastic materials with similar molecular structure, such as ABS or PC, the two shells of the lamp can be well welded by ultrasonic welding process. In the embodiment of the present invention, it is used for welding between the lens and the upper shell. , because the shape of the lens is simple, the ultrasonic fixture (that is, the upper fixture head 210 and the lower fixture head 220) is easy to manufacture, and the cost is low. The sealing structure of the above-mentioned LED lamp 100 is simple, and the sealing performance is very good, and there is no protection problem caused by poor coordination of the two materials. Moreover, the transparent part of the lamp is a lens, which can better reflect the light, and there is no need to add a reflector to reflect the anti-line. Such a process of combining the transparent part and the reflector can not only reduce the production process and cost, The reliability of the LED lamp 100 can also be improved. The traditional sealing design between the transparent part of the lamp and the shell uses a physical mechanical fastening structure: when two materials are combined, in order to ensure good protection, a rubber sealing ring is generally added between the two materials Or rubber seal structure, and then use fasteners and standard parts to tighten, so that the sealing ring can generate compression to prevent dust and water. At the same time, it is necessary to add a reflector to the transparent part of the traditional LED lamp to reflect the light. Such a structure often has a lot of materials and a large volume, and the problem of protection failure is likely to occur between too many materials.

The above-mentioned embodiments only express several implementation modes of the present invention, and the description thereof is relatively specific and detailed, but should not be construed as limiting the patent scope of the present invention. It should be pointed out that those skilled in the art can make several modifications and improvements without departing from the concept of the present invention, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the patent for the present invention should be based on the appended claims.

Claims (10)

1. a LED light fixture is characterized in that, comprising:

Upper casing has accepting groove, and the bottom of described accepting groove offers loophole;

Lens are contained in the described accepting groove and hide described loophole;

Lower casing has the electrical equipment groove, and described lower casing is fixedly connected with the side of described upper casing near described loophole place near a side at the opening place of described electrical equipment groove, so that described loophole is connected with described electrical equipment groove;

Drive circuit board is contained in the described electrical equipment groove, and corresponding setting with described loophole; And

LED is directly fixed on the described drive circuit board, and is contained in the described loophole;

Wherein, described upper casing and lens are made by two kinds of similar plastic materials of molecular structure respectively, and described lens are made by transparent plastic; The mode of described lens by ultrasonic bonding directly links together with the sidewall melting of the accepting groove of described upper casing, to seal the opening of described accepting groove.

2. LED light fixture as claimed in claim 1 is characterized in that, the bottom of described electrical equipment groove is provided with fixed leg, and described drive circuit board is fixed on the described fixed leg.

3. LED light fixture as claimed in claim 2 is characterized in that, the free-ended end face of described fixed leg is provided with positioning boss, and described drive circuit board offers the locating hole that passes for described positioning boss.

4. LED light fixture as claimed in claim 1 is characterized in that, described upper casing is provided with locating dowel near a side at described loophole place, and described lower casing offers the locating slot of accommodating described locating dowel near a side correspondence at the opening place of described electrical equipment groove.

5. LED light fixture as claimed in claim 4, it is characterized in that, described locating dowel is offered screw at its free-ended end face, the bottom of described locating slot offers the through hole that passes for threaded fastener, and described threaded fastener is screwed with the screw of described locating dowel and described upper casing is fixedly connected with described lower casing.

6. LED light fixture as claimed in claim 5 is characterized in that, described locating dowel is annular, and described locating slot is the groove of annular; Described light fixture also comprises sealing ring, and described sealing ring is contained in the locating slot, and arranges near the inboard of described locating slot; The free-ended end face of described locating dowel and described sealing ring butt.

7. LED light fixture as claimed in claim 1 is characterized in that, described lens have the arc exiting surface, and described arc exiting surface protrudes outside the described upper casing.

8. LED light fixture as claimed in claim 7 is characterized in that, the side that described lens are relative with described arc exiting surface is formed with boss, and described boss is contained in the described loophole.

9. LED light fixture as claimed in claim 1 is characterized in that, the bottom of described electrical equipment groove also is provided be used to the support column that supports described drive circuit board middle part.

10. manufacture method such as each described LED light fixture of claim 1～9, it comprises the steps:

Clamp head and the lower clamp head relative with described upper clamp head are provided, and described upper clamp head is used for the described lens of clamping, and described lower clamp head is used for the described upper casing of clamping;

Described upper clamp head moves towards described lower clamp head, until described lens are contained in the accepting groove of described upper casing; And

Adopt the contact position of the sidewall of the described lens of ultrasonic irradiation and described upper casing accepting groove, the contact position of sidewall of the accepting groove of described lens and described upper casing is welded together.

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