CN105909996B - Production process of LED glass bulb and LED glass bulb based on production process - Google Patents
Production process of LED glass bulb and LED glass bulb based on production process Download PDFInfo
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- CN105909996B CN105909996B CN201610314874.3A CN201610314874A CN105909996B CN 105909996 B CN105909996 B CN 105909996B CN 201610314874 A CN201610314874 A CN 201610314874A CN 105909996 B CN105909996 B CN 105909996B
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- 239000011521 glass Substances 0.000 title claims abstract description 74
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 63
- 238000005245 sintering Methods 0.000 claims abstract description 35
- 238000000034 method Methods 0.000 claims abstract description 15
- 230000008569 process Effects 0.000 claims abstract description 11
- 241000217776 Holocentridae Species 0.000 claims description 22
- 239000011261 inert gas Substances 0.000 claims description 10
- 238000003466 welding Methods 0.000 claims description 10
- 230000005855 radiation Effects 0.000 claims description 4
- 238000010438 heat treatment Methods 0.000 claims 1
- 238000009434 installation Methods 0.000 abstract description 6
- 230000000694 effects Effects 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000012536 packaging technology Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000005086 pumping Methods 0.000 description 2
- 238000000137 annealing Methods 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012858 packaging process Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Images
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
- F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
- F21K9/90—Methods of manufacture
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21V19/00—Fastening of light sources or lamp holders
- F21V19/001—Fastening of light sources or lamp holders the light sources being semiconductors devices, e.g. LEDs
- F21V19/0015—Fastening arrangements intended to retain light sources
- F21V19/0025—Fastening arrangements intended to retain light sources the fastening means engaging the conductors of the light source, i.e. providing simultaneous fastening of the light sources and their electric connections
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21V23/00—Arrangement of electric circuit elements in or on lighting devices
- F21V23/003—Arrangement of electric circuit elements in or on lighting devices the elements being electronics drivers or controllers for operating the light source, e.g. for a LED array
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- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Non-Portable Lighting Devices Or Systems Thereof (AREA)
Abstract
According to the production process, the driving chip and the LED luminous body are fixed to the front end of the glass column in the lamp core production step, so that a driving chip installation step is required to be added at the later production stage, the production process is basically consistent with the traditional incandescent lamp production process, the automatic production can be conveniently realized by using the existing incandescent lamp production equipment, the production efficiency is effectively improved, and the production cost is reduced; more importantly, the shielding jig is arranged in the sintering step, so that the heat of flame is blocked from being transmitted to the driving chip, the driving chip is prevented from being burnt out in the sintering process, and the yield of production is greatly improved.
Description
Technical Field
The invention relates to the technical field of LED bulbs, in particular to a production process of an LED glass bulb and the LED glass bulb based on the production process.
Background
The incandescent lamp is the most widely used lighting lamp in traditional lighting, especially in the special lighting field such as christmas lamp, and the incandescent lamp is basically used for lighting conventionally. The general production process of incandescent lamps is: the lamp filament is fixed to the front end of the hollow glass column, the lamp filament is communicated to the bottom end of the glass column through the jumper, then the glass column is inserted into the glass lampshade, then the opening of the glass lampshade is heated by flame, the glass column and the glass lampshade are sintered together, namely, the glass lampshade can be communicated with the outside only through a tube cavity in the hollow glass column, then the air in the lampshade is pumped out from the tube cavity in the hollow glass column and is filled with inert gas by using air pumping and inflating equipment, so that the lamp filament is prevented from being oxidized, after air pumping is completed, only the lamp cap used for taking electricity needs to be fixed, and certainly, the lamp cap needs to be in point connection with the jumper. Since incandescent lamp products are well-developed, there are currently well-developed production facilities.
However, with the popularization of LED technology, LED lamps are currently used in many lighting fields to replace traditional incandescent lamps, even in special lighting fields such as christmas lamps.
Originally, LED bulbs used to replace christmas lights were built into plastic lampshades with one or more in-line packaged LED beads due to limitations in LED packaging processes, bulb manufacturing processes, and the like. Although the LED bulb produced by the method has a simple structure, the luminous efficiency is very low, the energy consumption level is high, and more importantly, the luminous effect of the LED lamp produced by the method is far inferior to that of the traditional incandescent lamp, so that the product is difficult to meet the requirement of Christmas lighting, and some of the LED lamps even meet the standard requirement of European and American countries on the Christmas lamp.
Therefore, with the development of LED packaging technology, it is proposed in the industry to replace the filament of the traditional incandescent lamp with the LED filament produced by the new packaging technology, such as the LED filament sheet bulb disclosed in chinese patent application No. 201410110172.4 proposed by the applicant, and to simulate the incandescent lamp, and to evacuate the bulb and fill inert gas into the bulb, thereby prolonging the service life of the LED filament and making the light emitting effect as consistent as possible with the incandescent lamp. Specifically, the production process of the LED filament lamp is basically the same as that of the traditional incandescent lamp, but because the LED chip usually works in a low-voltage constant-current environment, the LED filament cannot be directly supplied with power by mains supply, and a driving power supply is needed to convert the mains supply into low-voltage constant-current power and then supply the low-voltage constant-current power to the LED filament through a jumper. Therefore, at present, a process needs to be added on the traditional production process of the incandescent lamp, namely, after the inert gas is filled, the lamp holder cannot be directly fixed, but the driving chip is connected to one end of the jumper wire firstly, then the power-taking lamp holder is installed and then electrically connected with the driving chip, because of the reasons of relative complexity, structural characteristics of products and the like, the process is difficult to realize automatic production, and after the bulb filled with the inert gas is produced by using traditional equipment, manual production needs to be changed, the production efficiency is low, and further, the product cost is high.
Disclosure of Invention
The invention aims to avoid the defects in the prior art and provide the production process of the glass bulb, which is beneficial to adopting automatic production, thereby greatly improving the production efficiency and reducing the production cost.
The invention idea is as follows: considering that it is inconvenient to automatically assemble the driving chip in the later stage of production, the inventor considers that the adjustment process flow is adjusted, namely the driving chip is installed in advance, and preferably, the driving chip is installed in the filament installation link, because the driving chip is used for supplying power to the filament, the installation position of the driving chip is inevitably required to be changed, and by comprehensive consideration, the inventor installs the driving chip and the filament to the front end of the glass column, and because the tail end of the glass column has a little redundant length, a part of the driving chip needs to be trimmed in the later stage. However, although the fixing of the LED driving chip to the front end of the glass lamppost can omit the later mounting step of the driving chip, the inventor finds that the method also brings new problems: in order to avoid the influence of the driving chip on the lighting effect, the driving chip is generally relatively close to the opening, and in the processing process, in order to sinter the glass lampshade and the glass column together, flame needs to be sprayed towards the opening, so that radiation (including strong light, infrared rays and the like) emitted by the flame can heat the driving chip, and the temperature of the driving chip is rapidly increased. Therefore, the inventors conceived of improving the sintering process so as to avoid burning out the driving chip during the sintering process.
The purpose of the invention is realized by the following technical scheme:
the production process of the LED glass bulb comprises the following steps:
a lamp wick production step: the LED module is fixed at the front end of the hollow glass column to form a glass lamp wick, and the LED module is electrically connected with an LED luminous body and a driving chip;
a step of assembling: the lamp wick penetrates into the lampshade from the opening of the lampshade, so that the front end of the glass column of the lamp wick is arranged in the lampshade, and the tail end of the glass column is arranged outside the lampshade;
sintering: the opening of the lampshade is heated by flame from the outside of the lampshade, so that the opening of the lampshade and the opening of the glass column are fused with the glass column, a shielding jig is arranged on the outer side of the lampshade, the shielding jig blocks part of radiation emitted by the flame to form a shadow covering the driving chip, and the heat of the flame is blocked and transmitted to the driving chip.
In the sintering step, the flame is sprayed in the horizontal direction, and the driving chip falls into a projection shadow formed on the vertical surface by the shielding jig.
Wherein the sintering step sequentially comprises a pre-sintering step, a high-temperature sintering step and a temperature-reducing sintering step, the intensity of the flame in the pre-sintering step and the annealing step is smaller than that in the high-temperature sintering step, and the shielding jig is only arranged in the high-temperature sintering step.
Wherein, still include the evacuation step: the air in the lampshade is extracted through the tube cavity of the glass lamp wick, so that the vacuum is formed in the lampshade.
Wherein, still include inert gas filling step: the inert gas is filled into the lampshade through the tube cavity of the glass lamp wick.
In the wick production step, the driving chip is a sheet-shaped driving chip, the bottom end of the driving chip is connected with the top end of the glass column, and the top end of the driving chip is connected with the LED luminous body.
In the wick production step, the LED luminous body is a sheet-shaped LED luminous body, the bottom of the LED luminous body is provided with a power taking welding point, and the top end of the driving chip is provided with a corresponding power supply welding point.
The LED glass bulb comprises a lampshade and a glass lamp wick arranged in the lampshade, the glass lamp wick comprises a hollow glass column and a sheet-shaped driving chip fixed at the top end of the glass column, and the top end of the driving chip is connected with an LED luminous body.
The LED luminous body is a sheet-shaped LED luminous body, the bottom of the LED luminous body is provided with a power taking welding point, and the top end of the driving chip is provided with a corresponding power supply welding point
The invention has the beneficial effects that: according to the production process, the driving chip and the LED luminous body are fixed to the front end of the glass column in the lamp core production step, so that a driving chip installation step is not required to be added in the later production stage, the production process is basically consistent with the traditional incandescent lamp production process, the automatic production can be conveniently realized by using the existing incandescent lamp production equipment, the production efficiency is effectively improved, and the production cost is reduced; more importantly, the shielding jig is arranged in the sintering step, so that the heat of flame is blocked from being transmitted to the driving chip, the driving chip is prevented from being burnt out in the sintering process, and the yield of production is greatly improved.
Drawings
The invention is further illustrated by means of the attached drawings, but the embodiments in the drawings do not constitute any limitation to the invention, and for a person skilled in the art, other drawings can be obtained on the basis of the following drawings without inventive effort.
Fig. 1 is a schematic structural diagram of an LED glass bulb according to the present invention.
Detailed Description
The invention is further described with reference to the following examples.
The invention provides an LED glass bulb, which is particularly suitable for producing Christmas lamps meeting American standards through actual measurement, and the Christmas lamps adopting the structure can better meet various parameter indexes of the Christmas lamps of models such as American C7, C9, E12, E17, G30, G40, G50 and the like. Specifically, this LED glass bulb includes lamp shade 1, sets up the glass wick in lamp shade 1, the glass wick includes hollow glass post 2 and is fixed in the flaky driver chip 3 on 2 tops of glass post, driver chip 3's top is connected with the LED luminous element. The LED luminous body 4 is a sheet-shaped LED luminous body 4, the bottom of the LED luminous body 4 is provided with a power taking welding point, and the top end of the driving chip 3 is provided with a corresponding power supply welding point. The advantage of the product of this structure is that can drive chip 3 and LED luminous element 4 and fix to 2 front ends on the glass post together when producing, consequently need not increase a drive chip 3 installation steps in the production later stage, and its production technology is unanimous basically with traditional incandescent lamp production technology, and the current incandescent lamp production facility of utilization that can be convenient realizes automated production, effectual improvement production efficiency, reduction in production cost. Moreover, the LED luminous body 4 is fixed on the top end of the driving chip 3, so that the driving chip 3 cannot shield the LED luminous body 4, other shielding does not exist around the LED luminous body 4, and the luminous effect is better. Furthermore, the sheet-shaped LED luminous body 4 is adopted, so that the production and the processing are more convenient, and the light emission is more uniform.
The specific implementation mode of the production process adopted by the bulb comprises the following steps:
a lamp wick production step: the LED module is fixed at the front end of the hollow glass column 2 to form a glass lamp wick, and the LED module is electrically connected with an LED luminous body 4 and a driving chip 3;
a step of assembling: the lamp wick penetrates into the lampshade 1 from an opening of the lampshade 1, so that the front end of a glass column 2 of the lamp wick is arranged in the lampshade 1, and the tail end of the glass column 2 is arranged outside the lampshade 1;
sintering: the method comprises a pre-sintering step, a high-temperature sintering step and a temperature-reducing sintering step in sequence, wherein flames are sprayed by igniters along the horizontal direction in the three steps, and the intensity of the flames in the pre-sintering step and the temperature-reducing sintering step is smaller than that of the flames in the high-temperature sintering step, so that the opening of the lampshade 1 is heated, and the opening of the lampshade 1 and the glass column 2 are fused together; in the high-temperature sintering step, a shielding jig is arranged on the outer side of the lampshade 1, and the shielding jig blocks part of radiation emitted by the flame to form a shadow covering the driving chip 3, so that the heat of the flame is blocked from being transmitted to the driving chip 3.
And (3) vacuumizing: air in the lampshade 1 is extracted through the tube cavity of the glass lamp wick, so that vacuum is formed in the lampshade 1.
Filling inert gas: inert gas is filled into the lampshade 1 through the tube cavity of the glass lamp wick.
Lamp holder installation: and (5) installing a lamp cap.
The steps are all realized through an automatic production mode.
In the production process, the shielding jig is arranged in the sintering step, so that the heat of flame is blocked and transmitted to the driving chip 3, the driving chip 3 is prevented from being burnt out in the sintering process, and the yield of production is greatly improved.
Finally, it should be noted that the above embodiments are only used for illustrating the technical solutions of the present invention, and not for limiting the protection scope of the present invention, although the present invention is described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that modifications or equivalent substitutions can be made on the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.
Claims (7)
1. A production process of an LED glass bulb is characterized by comprising the following steps:
a lamp wick production step: the LED module is fixed at the front end of the hollow glass column to form a glass lamp wick, and the LED module is electrically connected with an LED luminous body and a driving chip;
a step of assembling: the lamp wick penetrates into the lampshade from the opening of the lampshade, so that the front end of the glass column of the lamp wick is arranged in the lampshade, and the tail end of the glass column is arranged outside the lampshade;
sintering: heating the opening of the lampshade by flame from the outside of the lampshade so that the opening of the lampshade and the glass column are fused together, and arranging a shielding jig on the outer side of the lampshade, wherein the shielding jig blocks part of radiation emitted by the flame to form a shadow covering the driving chip so as to block the heat of the flame from being transferred to the driving chip;
the sintering step sequentially comprises a pre-sintering step, a high-temperature sintering step and a temperature-reducing sintering step, wherein the flame intensity of the pre-sintering step and the temperature-reducing sintering step is smaller than that of the high-temperature sintering step, and the shielding jig is only arranged in the high-temperature sintering step;
in the sintering step, the flame is sprayed in the horizontal direction, and the driving chip falls into a projection shadow formed on the vertical surface by the shielding jig.
2. The process for producing an LED glass bulb according to claim 1, further comprising the step of evacuating: the air in the lampshade is extracted through the tube cavity of the glass lamp wick, so that vacuum is formed in the lampshade.
3. The process for producing an LED glass bulb according to claim 1, further comprising an inert gas filling step of: the inert gas is filled into the lampshade through the tube cavity of the glass lamp wick.
4. The production process of the LED glass bulb as claimed in claim 1, wherein in the wick production step, the driving chip is a sheet-shaped driving chip, the bottom end of the driving chip is connected with the top end of the glass column, and the top end of the driving chip is connected with the LED luminous body.
5. The production process of the LED glass bulb as claimed in claim 1, wherein in the wick production step, the LED luminous body is a sheet-shaped LED luminous body, the bottom of the LED luminous body is provided with a power taking welding point, and the top end of the driving chip is provided with a corresponding power supply welding point.
6. An LED glass bulb processed by the production process of the LED glass bulb as claimed in any one of claims 1 to 5, which comprises a lampshade and a glass lamp wick arranged in the lampshade, and is characterized in that: the glass lamp wick comprises a hollow glass column and a sheet-shaped driving chip fixed at the top end of the glass column, and the top end of the driving chip is connected with the LED luminous body.
7. The LED glass bulb of claim 6, wherein: the LED luminous body is a flaky LED luminous body, the bottom of the LED luminous body is provided with a power taking welding point, and the top end of the driving chip is provided with a corresponding power supply welding point.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201610314874.3A CN105909996B (en) | 2016-05-13 | 2016-05-13 | Production process of LED glass bulb and LED glass bulb based on production process |
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| CN201610314874.3A CN105909996B (en) | 2016-05-13 | 2016-05-13 | Production process of LED glass bulb and LED glass bulb based on production process |
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| CN105909996B true CN105909996B (en) | 2022-10-21 |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN106764565B (en) * | 2017-01-26 | 2023-02-03 | 海宁市新宇光能科技有限公司 | Low-lamppost pile head LED filament lamp production equipment with small rotary platform |
| CN108799871A (en) * | 2018-07-07 | 2018-11-13 | 东莞市米蕾电子科技有限公司 | A kind of automatic production process of LED bulb |
| CN109185732B (en) * | 2018-09-11 | 2024-09-17 | 东莞市米蕾电子科技有限公司 | Full-automatic LED bulb production line |
| US12117154B1 (en) | 2023-11-03 | 2024-10-15 | Henan Yanxin Photoelectric Co., LTD | LED glass bulb and manufacturing method thereof |
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